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Full text of "Yamaha R6 (1999 - 2002) Service Manual"

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YZF-R6L 
YZF-R6CL 

Service Manual 






HOW TO USE THIS MANUAL 

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive 
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid 
out with the individual steps in sequential order. 

he manual is divided into chapters. An abbreviation and symbol in the upper right corner of each 
page indicate the current chapter. 
Refer to "SYMBOLS". 

apter is divided into sections. The current section title is shown at the top of each page, 
except in Chapter 3 ("PERIODIC CHECKS AND ADJUSTMENTS"), where the sub-section title(-s) ap- 
pears. 

(3) Sub-section titles appear in smaller print than the section title. 

tp identify parts and clarify procedure steps, there are exploded diagrams at the start of each 
removal and disassembly section. 

fi Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a 
disassembly step. 

h Symbols indicate parts to be lubricated or replaced. 
Refer to "•SYMBOLS". 

(7) A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of 
parts, notes in jobs, etc. 

)bs requiring more information (such as special tools and technical data) are described sequen- 
tially. 



;„ EN6 



■ A 



__ CLUTCH ; » 

! 8EMOW4G THE CLUTCH ■«*»-— -> 



O 



INFO . ^^® 






CHK ■ |Q| 
ADJ ■ Ht 



:00L ' SC 



CHAS ^3§> 





(13) 



I&&I 



ENG , vi 



CARBi ^ 



ELEC iF~~ 

fctiM fcim IH %«# | J 







A 




n a 



p.| 



Q 






® 



'23) 



i : 



»| -mmx 






: .--P '^wKlflr i '™"W '■;; 



SYMBOLS 

The following symbols are not relevant to every 

vehicle. 

Symbols (1) to (|) indicate the subject of each 

chapter. 

(1) General information 

(2) Specifications 

(S) Periodic checks: and adjustments 

(i) Engine? 

(5) Cooling system 

(|) Carburetor(-s) 

(?) Chassis 

(8) Electrical system 

(9) Troubleshooting 



Symbols© to® indicate the following. 

(ij| Serviceable with engine mounted 
(fj) Filling fluid 
@ Lubricant 
(j)| Special tool 

(14) Tightening torque 
@ Wear limit, clearance 
@) Engine speed 
(17) Electrical data 



Symbols (jj) to@) in the exploded diagrams indi- 
cate the types of lubricants and lubrication 

points. 

@ Engine oil 

(181 Gear oil 

«|C| Molybdenum disulfide oil 

6l) Wheel bearing grease 

i||) Lithium soap base grease 

@ ! Molybdenum disulfide grease 

Symbols® to© in the exploded diagrams indi- 
cate the following. 

pply locking agent (LOCTITE*) 
@) Replace the part 



INDEX 



GENERAL INFORMATION 


INFO ■_■ 


SPECIFICATIONS 


SPEclH| 


PERIODIC CHECKS AND 
ADJUSTMENTS 


ADJ B| 


ENGINE OVERHAUL 


ENG Ffl 


COOLING SYSTEM 


cootjEj 


CARBURETORS 


r ~WZ 

CARBBjV 


CHASSIS 


CHAs|Q| 


ELECTRICAL 


01 
£1 


TROUBLESHOOTING 


? 

TRBL'BTd 
SHTG KT^ 



SPEC 



CHAPTER 2, 
SPECIFICATIONS 

GENERAL SPECIFICATIONS ... 2-1 

ENGINE SPECIFICATIONS 242 

CHASSIS SPECIFICATIONS 2-41 

ELECTRICAL SPECIFICATIONS 2-15 

CONVERSION TABLE 2 -18 

TIGHTENING TORQUES 2-18 

GENERAL TIGHTENING TORQUES 

ENGINE TIGHTENING TORQUES , 

CHASSIS TIGHTENING TORQUES ..,..,, 2-22 

LUBRICATION POINTS AND LUBRICANT TYPES 2-23 

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2-23 

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES .... 2-24 

OIL FLOW DIAGRAMS , 2-25 

COOLANT FLOW DIAGRAMS . 2-29 

CABLE ROUTING 2 -33 



GENERAL SPECIFICATIONS 



SPECIFICATIONS 
GENERAL SPECIFICATIONS 



SPEC 



Item 


Standard | Limit 


Model code 


YZF-R6L: 5GV1 (U.S.A.) 
YZF-R6CL: 5GV2 (California) 
YZF la) 




Dimensions 

Overall length 
Overall width 
Overall height 
Seat height 
Wheelbcise 

Minimum ground clearance 
Minimum turning radius 


2025 mrn (79.7 in) 

890 mm (27.2 in) 

1105 mi 

820 mm (32.3 in) 

1380 mm (54.3 in) 

1385 mm (54.5 in) (California) 

135 mm (5.3 in) 

3400 mm (133.9 in) 




Weight 
Wet (with oil arid a full fuel tank) 

Dry (without oil and fuel) 

Maximum load (total of cargo, rider, 
passenger, and accessories) 


188 kg (415 lb) 

MjtU/ H'H<-alifomia) 

169 kg (373 lb) 

1 70 kg (375 lb) (California) 

375 kg (827 If)) 





2-1 



ENGINE SPECIFICATIONS 



SPEC 



ENGINE SPECIFICATIONS 



Item 


: Standard ] Limit 


Engine 




Engine tipe 


Liquid-cooled, 4-stroke, DOHC 


##• 


Displacement 


800 cm 3 (36,81 cu.in) 


### 


Cylinder arrangement 


Forward-inclined parallel 4-cylinder 


### 


Bore x stroke 


85,5 x 44,5 mm (2,58 x 1 ,75 in) 


• ## 


Compression ratio 


12,4: t 


### 


Engine idling speed 


1,250 ~ 1,350 r/min 


### 


Vacuum pressure at engine idling 


24,0 kPn ( 180 mrriHg, 7,0866 in Hg) 


### 


speed 






Standard compression pressure 


1550 kPa (15.5 kg/cm 2 , 224.75 psi) at 


### 


(at sea level) 


400 r/min 




Fuel 






Recommended fuel 


Regular gasoline 


$«ft# 


Fuel tank capacity 






Total (including reserve) 


17 L (3,74 Imp gal, 4.49 US gal) 


##• 


Reserve only 


3,5 L (0.77 Imp gal, 0,93 US gal) 


• ## 


Engine oil 






Lubrication system 


Wet sump 


### 


Recommended oil 




### 


c 


t" 10" 30* 5 


0' 70" 90" 110* 130'F 

1 l.dh ! 


lalube 4 (10 W 30) or SAE 10 W 

30 type SE motor oil (-10°C (10°F) 








~~<r~f>~l£ 








I 1 
I — 

j 


_4—]— 

1 


1 


or higher) 

kilube 4 (20 W 40) or SAE 20 W 
40 type SE motor oil (5°C (40° F) or 




2 


II 1 1 I 1 

)" -10" 0" 10" 20' 30" 40* 50t 


higher) 




Quantity 






Total amount 


3.5 L (3,08 Imp qt, 3,70 US qt) 


$#<§ 


Without oil filter cartridge 


2.5 L (2.20 Imp qt, 2,64 US qt) 


### 


replacement 






With oil filter cartridge replacement 


2,7 L (2,38 Imp qt, 2.85 US qt) 


### 


Oil pressure (hot) 


80 kPa (0.8 kg/cm 2 , 11.6 psi) at 1300 
r/min 


### 


Relief valve opening pressure 


450 550 kPa (4.5 ~ 5,5 kg/cm 2 , 85.3 

~ 79,8 psi) 


### 



2-2 



ENGINE SPECIFICATIONS 



SPEC 



Item 


iarci 


Limit 


Oil filtei 




1 ' 


Oil filter type 


Cartridge (paper) 


•## 


Bypass valve opening pressure 


80 -■• 120 kPa (0.8 - 1.2 kg/cm 2 . 11.6 
- 17.4 psi) 


### 


Oil pump 






Oil pump type 


Trochoidal 


### 


Inner-rotor-to-outer-rotor-tip 


0,03 ~ 0.09 mm (0.0012 - 0.0035 in) 




clearance 




(0.0059 in) 


Outer-rotor-to-oi!-pump-housing 


0,03 ~ 0.08 mm (0.0012 0.0031 in) 




clearance 




I (0.0059 in) 


Cooling system 




Radiator capacity 


2.15 L (2.27 US qt) 




Radiator cap opening pressure 


110 ~ 140 kPa (1.10 ~ 1.40 kg/cm 2 . 
16.0 ~ 20.3 psi) 


### 


Radiator core 






Width 


320 mm (12.8 in) 


mmm 


Height 


253 mm (10.2 in) 


• ## 


Depth 


24 mm (0.94 in) 


• #■• 


Coolant reservoir 






Capacity 


0,44 L. (0,4? US qt) 


### 


Water pump i 




Water pump type i Single-suction centrifugal pump 


##• 


Reduction ratio 86/44 x 31/31 (1.955) 


### 


Starting syslem type j Electric starter 




Spark plugs 




Model (manufacturer) x quantity 


CR10EK/NGK x 4 


#•# 




CR9EK/NGK x 4 (California) 


### 


Spark plug gap 


0.8 ~ 0.7 mm (0.02 0.03 in) 


■### 


Cylinder head 






Max. warpage 


### 


0.05 rnrn 
(0,002 in) 


■"»-. 


t 






f 


""'"-®H*,.. 












* "} \ i | 


( 


' 


• 


""■p." 

f 



2-3 



ENGINE SPECIFICATIONS 



SPEC 



Item 

Camshafts 
Drive system 

Camshaft cap inside diameter 
Camshaft journal diameter 
Camshaft-journa!-to-camshaftcap 
clearance 
Intake camshaft lobe dimensions 




Measurement A 

Measurement B 

Measurement C 
Exhaust camshaft lobe dimensions 



\ A 



'»" B - 



Measurement A 

Measurement B 

Measurement C 
Max. camshaft runout 



rii 



a i 






Standard 

Chain drive (right) 

23,000 - 23,021 mm (0.9055 - 0.9063 in) 

22.967 - 22.980 mm (0,9042 ~ 0.9047 in) 
0.020 0.054 mm (0.0008 ~ 0.0021 in) 



Limit 



33.05 - 33.15 mm (1.3012 - 1,3051 in) 

25,14 25.24 mm (0,9898 - 0.9937 in) 

7,81 3.01 mm (0.3075 ~ 0.3154 in) 



0.03 mm 
(0,0031 in) 



33.0 mm 
(1.3 in) 

25.09 mm 
(0,99 in) 



32,55 32.65 mm (1.; - 1,2854 in) 32,50 mm 

(1,28 in) 

25,07 - 25.17 mm (0.9870 ~ 0.9909 in) 25,02 mm 

I (0.99 in) 

7.33 ~ 7.58 mm (0.2906 ~ 0.2984 in) 

0.06 mm 
(0,0024 in) 



2-4 



ENGINE SPECIFICATIONS 



SPEC 



Item 



Timing chain 
Model /number of links 
Tensioning system 



Valves, walwe seats, walwe guides 
Valve clearance (cold) 

intake 

Exhaust 
Valve dimensions 



Standard 



RH2015/120 

Automatic 



0.11 - 0,20 mm (0.0043 0.0079 in) 

0.21 ~ 0.30 mm (0.0083 0.0118 in) 



Limi' 




Head Diameter Face Width 

Valve head diameter A 
Intake 
Exhaust 

Valve face width B 
Intake 
Exhaust 

Valve seat width C 
Intake 

Exhaust 

Valve margin thickness D 
Intake 

Exhaust 

Valve stem diameter 
Intake 

Exhaust 

Valve guide inside diameter 
Intake 

Exhaust 

Valve-stem-to-valve-guide clearance 

Intake 

Exhaust 
Valve stem runout 



Valve seat width 
Intake 



24,9 
21.9 



Seat Width 

25.1 mm (0.9808 
22.1 mm (0,8622 



D 



Margin Thickness 



1.14 1.98 mm 

1.14 - 1.98 mm 



0.9882 in 
0.8701 in 



in) 
in) 



0.9 1.1 mm (0.0354 - 0,0433 in) 

0.9 ■ 1.1 mm (0.0354 ~ 0.0433 in) 

0,8 ~ 0.8 mm (0.0236 0.0315 in) 

0.6 ~ 0.8 mm (0,0236 0.0315 in) 

3.975 - 3.990 mm (0.1565 ~ 0.1571 in) 

3,90)0 3,975 mm (0.1559 ~ 0.1585 in) 

4.000 4,012 mm (0.1575 0.1530 in) 

4.000 4,012 mm (0.1575 ~ 0,1580 in) 

0.010 ~ 0.037 mm (0.0004 0. i) 

0.025 - 0.052 mm (0.001 0.002 in) 



0.9 ~ 1.1 mm (0.0354 - 0,0433 in) 



1 ,6 mm 
i in) 

1 .6 mm 
(0,06 in) 

0.5 mm 

(0,02 in) 
0.5 mm 
(0.02 in) 

3.950 mm 
(0,1555 in) 
3.935 mm 
(0.1549 in) 

4.042 mm 
(0,1591 in) 
4.042 mm 
(0,1591 in) 

0.08 mm 
(0.0031 in) 
■0.1 mm 

(0.0039 in) 
0.04 mm 
{0.0016 in) 



1 .6 mm 
(0,06 in) 



2-5 



ENGINE SPECIFICATIONS 



SPEC 



11 


ndard 


Limit 


Valve springs 






Free length 






Intake (inner) 


37.0mrn (1.48 in) 


35 mm 
(1 .38 in) 


(outer) 


38.4 mm (1.51 in) 


38,5 mm 
(1.44 in) 


Exhaust 


41.7 mm (1.64 in) 


39.5 mm 
(1.56 in) 


Installed length (valve closed) 






Intake) (inner) 


30.0 mm (1.18 in) 


••• 


(outer) 


32.5 mm (1.28 in) 


••• 


Exhaust 


38.1 mm (1.42 in) 


### 


Compressed spring force 






(installed) 






Intake (inner) 


89 ~ 79 N (15.51 -■■• 17.78 to, 
7.04 - 8.08 kg) 


•## 


(outer) 


114 - 132N (25.63 - 29.671b, 
11.62 ~ 13,48 kg) 




Exhaust 


180 - 184 N (35.97 41.38 11), 

18.32 - 18.78 kg) 


••• 


Spring tilt 








Intake (inner) 


### 


2.5°/ 1.6 mm 
(0.08 in) 


(outer) 




2.5° /1.7 mm 

(0.07 in) 


Exhaust 


••• 


2.5° /1.8 mm 
(0.07 in) 


Winding direction (top view) 






Intake (inner) 


Counter clockwise 


### 


(outer) 


Clockwise 


### 


Exhaust: 


Clockwise 


*## 


Cylinders 






Cylinder arrangement 


Forward-inclined, parallel 4-cylinder 


$## 


Bore x stroke 


85.5 x 45.5 mm (2.58 x 1,75 in) 


#*# 


Compression ratio 


12.4; 1 


### 


Bore 


85.50 ~ 85,51 mm (2.5787 ~ 2,5791 in) 


«•• 


Max. taper 


••• 


0.05 mm 
(0.002 in) 


Max. out-of-round 


### 


0.05 mm 
(0.002 in) 



2-8 



ENGINE SPECIFICATIONS 



SPEC 



Item 



Pistons 
Piston-to-cylinder clearance 

Diameter D 



Height H x. d 

Piston pin bore (in the pi; 

Diameter 

Offset 

Offset direction 
Piston pins 

Outside diameter 

Piston-pin-to-piston-pin- 
clearance 
Piston rings 

Top ring 



bore 



V 



Ring type 

Dimensions (B x T) 
End gap (installed) 

Ring side clearance 
2nd ring 



Ring type 

Dimensions (B x T) 
End gap (installed) 

Ring side clearance 
Oil ring 



B 



Dimensions (B x f 
End gap (installed) 



Standard 



0.025 ~ 0,050 mm (0,001 ~ 0.(302 in) 
85.460 ~ 65.475 mm (2.5772 ~ 2.5778 in) 



4 mm (0.16 in) 

16.002 16.013 mm (0.6300 

0,5 mm (0.0197 in) 
Intake side 

15.991 - 16.000 rum (0.6296 

0.002 0.022 mm (o'.00008 

in) 



Limit 



0.07 mm 
(0.0028 in) 



0.6304 in) 



0.8299 in) 
0.0009 | 0,072 mm 
(0.0028 in) 



Barrel 

0,80 x 2.45 mm (0.03 x 0.10 in) 
0.15 ~ 0.25 mm (0.006 - 0.0(39 in) 

0,030 ■ 0.085 mm (0,0012 ~ 0.0026 in) 



Taper 

0.8 x 2.5 mm (0.03 x 0.10 in) 

0.40 0.50 mm (0.016 ~ 0.020 in) 

0.020 0.055 mm (0.0008 ~ 0.0022 in) 



1 .5 x 2.3 mm (0.06 x 0.09 in) 
0.10 - 0.35 mm (0.00-1 0.0 1 4 in) 



0,50 mm 
(0.02 in) 
0.115 mm 
(0.05 in) 



0.85 mm 
(0.033 in) 
0.115 mm 

(0.05 in) 






2-7 



ENGINE SPECIFICATIONS 



SPEC 



Item J Standard 


Limit 


Connecting rods 






Crankshaft pin-to-big-end-bearing 


0,028 ~ 0,052 mm (0.0011 ~ 0.0020 in) 


••• 


clearance | 




Bearing color code j 1 = Blue 2 = Black 3 = Brown 4 = Green 


#•# 


Crankshaft 

f 

l.Z 

A 


n (c) 

I III lit ! 
I ilj \ \ \ 

J|e| I j 

„..iu d 


(C) 

1 lij 




C) 
k\ i 




""I 1 




#•# 


Wi " B 


268.8 - 270,0 mm (10,58 - 10,63 in) 


#•• 


Max, runout C 




0,03 mm 
(0.0012 in) 


Big end side clearance D 


0.160 0,262 mm (0.0063 - 0,0103 in) 


### 


Crankshaft-journal-to-crankshaft- 


0,034 ~ 0.058 mm ~ 0.0023 in) 


• •• 


journal-bearing clearance 






Bearing color code | = White 1 = Blue 


• #• 


I 2 = Black 3 = Brown 




| 4 = Green 




Clutch 




Clutch type 


Wet, multiple disc 




Clutch release method 


Rack and pinion (pull rod type) 




Clutch release method operation 


Cable operation 




Operation 


Left hand operation 




Clutch cable free play (at the end 


10 - 15 mm (0,39 ~ 0.59 in) 




of the clutch lever) 






Friction plates 






Thickness 


2,9 ~ 3.1 mm (0.11 - 0.12 in) 


2.8 mm 
(0,1102 in) 


Plate quantity 


8 


••• 


Clutch plates 






Thickness 


1.9 2.1 mm (0.07 - 0,08 in) 


### 


Plate quantity 


7 


#•» 


Max, warpage 


### 


(0,0039 in) 


Clutch plate 






Thickness 


2,2 2.4 mm (0.087 0,094 in) 




Plate quantity 


1 




Max. warpage 


••• 


0.1 mm 
(0,0039 in) 


Clutch springs 






Free length 


55 mm (2,17 in) 


54 mm 


j 


(2.13 in) 


Spring quantity I 6 


### 



2-8 



ENGINE SPECIFICATIONS 



SPEC 



Item 


T— — — — — — — —_— — __-__-________^ 

Standard 


Limit 


Transmission 






Transmission type 


Constant mesh, 6-speed 


•#• 


Primary reduction system 


Spur gear 


### 


Primary reduction ratio 


86/44(1.9545) 


••• 


Secondary reduction system 


Chain drive 


### 


Secondary reduction ratio 


48/16(31)00) 


••• 


Operation 
Gsoir f'cttios 


Left-foot operation 


### 


1st gear 


37/13(2,848) 


•## 


2nd gear 


37/19 (1.947) 


••• 


3rd gear 


28/18 (1.555) 


### 


4th gear 


32/24(1.333) 


•#• 


5th gear 


25/21 (1.190) 


##• 


6th gear 


28/24 (1.083) 


### 


Max. main axle runout 


### 


0.02 mm 
(0.0008 in) 


Max. drive axle runout 


### 


0.02 mm 
(0.0008 in) 


Shifting mechanism 






Shift mechanism type 


Cam drum 


• •• 


Max. shift fork guide bar bending 


### 


0.05 mm 
(0.002 in) 


installed shift rod length 


242 mm (9.52 in) 


##• 


Air filter type 


Wet element 


mm® 


Fyei pymp 






Pump type 


Electrical 


#•• 


Model (manufacturer) 


5EB (MITSUBISHI) 


##■# 


Output pressure 


15 - 20kPa(0.15 - 0.2 kg/cm 2 , 

2.2 ~ 2.9 psi) 


• •* 


Carburetors 






Model (manufacturer) x quantity 


CVRD37 (KEIHIN) x 4 


#•# 


Throttle cable free play (at the 


8 ~ 8 mm (0,24 0.31 in) 


### 


flange of the throttle grip) 






rk 


5GV101, 5GV210 (California) 


### 


Main jet 


Carburetors 1 and 4; #152, #148 (California) 


### 




Carburetors 2 and 3: #148 


#■## 


Main air jet 


#110 


### 


Jet needle 


Carburetors 1 and 4: N7SB 


##« 




Carburetors 2 and 3: N7SA 


### 


Needle jet 


2.6 


### 


Pilot air jet 


Carburetors 1 and 4: #105 


mmm 




Carburetors 2 and 3: #110 


#•# 


Pilot outlet 


0.9 


#« 


Pilot jet 


#38, #35 (California) 


• •• 


Bypass 1 


0,8 


##• 


Bypass 2 


0.8 


#$# 


pass 3 


0.8 


### 


Valve seat size 


1.2 


### 



ENGINE SPECIFICATIONS 



SPEC 


..- 



It Standard 


Limit 


Sic 

Starter jet 2 

Butterfly valve size 

Fuel level (below the line on the 

float chamber) 


... 
0,8 
#110 
17.5 ~ 18.5 mm (0.89 ~ 0,73 in) 



2-10 



CHASSIS SPECIFICATIONS 



SPEC 



CHASSIS SPECIFICATIONS 



item 



Frame 
Frame type 
Caster angle 
Trail 



Front wheel 
Wheel type 
Rim 

Size 

Material 
Wheel travel 
Wheel runout 

Max., radial wheel runout 

Max. lateral wheel runout 



Rear wheel 
Wheel type 
Rim 

Size 

Material 
Wheel travel 
Wheel runout 

Max- radial wheel runout 

Max. lateral wheel runout 



Front tire 
Tire type 
Size ' 
Model (manufacturer) 



Tire pressure (cold) 
« 90kg(0 - 198 1b) 

90 ~ 187 kg (198 - 412(h) 

High-speed riding 
Min. tire tread depth 



Standard 



Diamond 

24° 

81 mm (3.19 in) 



Limit 



Cast wheel 

17 x MT3.50 

Aluminum 

130 mm (5.12 in) 



Cast wheel 

17 x MT5.50 
Aluminum 

120 mm {4.72 in) 






1 mm 
(0.04 in) 
0.5 mm 

(0.02 in) 



••• 



Tubeless 

120/60ZR17(55W) 
BRiDGESTON BT56FE 
DUNLOP D207FJ 



250 kPa (2.5 kg/cm 2 , 38.3 psi) 
250 kPa (2.5 kg/cm 2 , 36.3 psi) 
250 kPa (2.5 kg/cm 2 , 38,3 psi) 



t mm 
(0.04 in) 
0.5 mm 

(0.02 in) 



1.6 mm. 

(0.06 in) 



2-11 



CHASSIS SPECIFICATIONS 



5 | spec j tr- 1 



Item 


Standard 


I Limit 


Rear tire 




lire type 


Tubeless 


### 


Size 


180/55 ZR 17 (73 W) 


mmm 


Model { man ufactu rer) 


BRIDGESTON BT56R-E 

DUNLOP D207-N 


mm* 


Tire pressure (cold) 






90 kg (0 - 198 lb) 


250 kPa (2,5 kg/cm 2 , 38.3 psi) 


■### 


90 • 187 kg (198 412 1b) 


290 kPa (2.9 kg/cm 2 , 42,1 psi) 


#■## 


High-speed riding 


250 kPa (2.5 kg/cm 2 , 36.3 psi) 




Min. tire tread depth 


### 




Front brakes 






Brake type 


Dual-disc brake 


■##■# 


Operation 


Right-hand operation 


### 


Recommended fluid 


DOT 4 


### 


Brake discs 






Diameter x thickness 


298 x 5 mm (11.73 x 0,20 in) 


• ## 


Min, thickness 


••• 


4,5 mm 
(0.18 in) 


Max, deflection 


••• 


0.1 mm 

(0.0039 in) 


Brake pad lining thickness 


5.5 mm (0.22 in) 


0,5 mm 
(0^02 in) 


• f * 






Master cylinder inside diameter' 


14 mm (0,55 in) 


### 


Caliper cylinder inside diameter 


30.2 mm (1.19 in) and 27 mm (1.06 in) 


### 


Rear brake 






Brake type 


Single-disc brake 


### 


Operation 


Right-foot operation 


### 


Brake pedal position (from the top 


4.3 ~ 9.3 mm (0.17 ~ 0.37 in) 


### 


of the brake pedal to the bottom of 






the rider footrest bracket bolt center.) 






Recommended fluid 


DOT 4 


##• 


Brake discs 






Diameter x thickness 


220 x 5 mm (8.88 x 0.20 in) 


### 


Min, thickness 


### 




Max. deflection 


### i 




Brake pad lining thickness 

! : » 

"" r ™^-»—™-™™ ™™..„™™,„™„™™™^x.,. i... , 


5 mm (0.2 in) 




i -, '•■—— ,,,„. ...,.„.„ „ — /'...........„, i *T" 1 

k 1 

[ 

Master cylinder inside diameter 


12.7 mm (0.5 in) 


••« 


Caliper cylinder inside diameter j 


27,0 mm (1.06 in) and 22.2 mm (0.87 in) 


### 



2-12 



CHASSIS SPECIFICATION 


SPEC - 






ItKtlt 


Standard 


it 


Front suspension 


p™"""""" """™"" : " """* ™ — ™™" ™™™™„ »™™™ — „„„.,„, „,„_„ — «„,,,.,.,,.., 




Suspension type 


Telescopic fork 


•#• 


Front fork type 


Coil spring/oil damper 


### 


Front fork travel 


130 mm (5.12 in) 


### 


Spring 






Free length 


251,8 mm (9,91 in) 


246 mm 
(9.69 in) 


Spacer length 


125 mm (4.92 in) 


### 


Installed length 


247,8 mm (9.76 in) 


### 


Spring rate (K1) 


7.5 N/mm (0.75 kg/mm, 42.83 lb/in) 




Spring stroke (K1 ) 


130 mm (0.00 ~ 5,12 in) 


mm® 


Optional spring available 


No 


mmm 


Fork oil 






Recommended oil 


Suspension oil "01" or equivalent 


• ## 


Quantity (each front fork leg) 


478 cm 3 (16.09358 US oz) 


• ## 


Level (from the top of the innertube, 


107 mm (4.21 in) 


### 


with the inner tube fullycompressed, 






and without thefork spring) 






Damper adjusting rod locknut distance 


25 mm (0.98 in) 


##• 


Spring preload adjusting positions 






Minimum 


8 


#$# 


Standard 


7.5 


### 


Maximum 


1 


### 


Rebound damping adjusting positions 






Minimum* 


9 


### 


Standard* 


8 


### 


Maxim urn* 


1 


###■ 


Compression damping adjusting j 






positions I 






Minimum* I 


10 


• ## 


Standard* 


6 


### 


Maximum* i 


1 


### 


*from the fully turned-in position | 


—————————— -—-^^ 



2-13 



CHASSIS SPECIFICATIONS 



SPEC 



Item 


Standard 


Limit 




Steering 










Angular bail bearings 


### 




Rear suspension 








Suspension type 


Swingarm (link suspension) 


• ** 




Rear shock absorber assemblytype 


Coii spring/gas-oil clamper 


• •• 




Rear shock absorber assemblytravel 

Qrifinn 


80 mm (2.36 in) 


##■# 




Free length 








Installed length 


189,5 mm (6.87 in) 


### 




Spring rate (K1) 


159 mm (6.28 in) 


### 




Spring stroke (K1) 


95.1 N/mm (9.51 kg/mm, 543.02 lb/in) 


##• 




Optional spring available 


~ 60 mm (0.00 2.36 in) 


### 




Standard spring preload gas/air 


No 


• •* 




pressure 


1,200 kPa (12 kg/cm 2 , 174 psi) 


### 




Spring preload adjusting positions 








Minimum 


t 


##• 




Standard 


4 


### 




Maximum 


9 


• *• 




Rebound damping adjusting positions 








Minimum* 


25 


### 




Standard* 


9 


### 




Maximum* 


t 


■•## 




Compression damping adjusting 








positions 








Minimum* 


13 


### 




Standard* 


7 


### 




Maximum* 


1 


### 




*from the fully turned-in position 








Swingarm 








Free play (at the end of the swingarm) 








Radial 


••• 






Axial 


••• 




_ 


Drive chain 




Model (manufacturer) 


532ZLV KAi (DID) 


### 




Link quantity 


118 


• •• 




Drive chain slack 


40 ~ 50 mm (1.57 ~ 1.97 in) 


#■## 




Maximum ten-link section 


149 mm (5.87 in) 


### 





2-14 



ELECTRICAL SPECIFICATIONS 


-* 


ELECTRICAL SPECIFICATIONS 




Item 


( tandard 


Limit 




System voltage 


1 


•## 


Ignition system 








Ignition system type 


C.D.I. 


••• 




Ignition timing 


10° BTDCat 1300r/min 


#•# 






I 5° BTDC at 1300 r/min (California) 


### 




Advanced timing 


55° BTDC at 5250 r/min 


### 




Advancer type 


i Throttle position sensor and electrical 


••• 




Pickup coil resistance/color 


248 372 £2/Gy-B 


### 




Transistorized coil ignition unit model 


F8T362 (MITSUBISHI) 


••# 




(manufacturer) 








Ignition coils 








Model (manufacturer) 


F6T549 (MITSUBISHI) 


### 




Minimum ignition spark gap 


8 mm (0.24 in) 


##* 




Primary coii resistance 


0.204 0.276 £2 


#«• 




Secondary coil resistance? 


8.5 - 11.5 kO 


•#• 




Throttle position sensor standard 




•*• 




resistance 








Charging system 








System type 


AC magneto 


mmm 




Model (manufacturer) 


F4T366 (MITSUBISHI) 


##• 




Nominal output 


14 V/320W at 5.000 r/min 


• #■# 




Stator coii resistance 


0.27 ~ 0.33 £2 at 20 °C (68 °F) 


### 




Voltage regulator 








Regulator type 


Semiconductor, short circuit type 


### 




Model (manufacturer) 


SH650A-12 (SHINDENGEN) 


### 




i-load regulated voltage 


14.1 14.9V 


mm® 




Rectifier 








Model 


SH650A-12 


##• 




Rectifier capacity 


18 A 


##• 




Withstand voltage 


200 V 


### 




Battery 








Battery type 


GT12B-4 


### 




Battery voltage /capacity 


12 V/10AH 


### 




Headlight type 


Halogen bulb 




Indicator light type • quantity j 




, 


Bulbs (voltage/wattage x quantity) j 








Headlight 


12V60W/55W x 2 


### 




Tail /brake light | 


12 V21 W/5 W x 2 


### 




Turn signal/position light j 


12 V27 W/8 W x 2 (front) 


#$# 






12V27W x 2 (rear) 


### 





2-15 



ELECTRICAL SPECIFICATIONS 



SPEC 



item 


Standard 


Limit 


Meter light 12 V 1.4 W x 2 


••• 


Electric starting system 






System type 


Constant mesh 


##• 


Starter motor 






Model (manufacturer) 


SM-U(MITSUBA) 


•»# 


Power output 


0.8 kW 


##• 


Brushes 






Overall length 


10 rum (0.39 in) 


3.5 mm 
(0.14 in) 


Spring force? 


7.16 - 9.52 N (730 970 g, 

25.77 34.27 oz) 


••• 


Commutator resistance 


0.012 ~ 0.022 Q 


•#• 


Commutator diameter 


28 mm (1.1 in) 


27 mm 
(1.06 in) 


Mica undercut 


0.7 mm (0.03 in) 


### 


Starter relay 






Model (manufacturer) 


MS5F-631 (JIDECO) 


### 


Amperage 


180 A 


###■ 


Coil resistance 


4.18 ~ 4.62 iJ 


### 


Horn 






Horn type 


Plain 


### 


Model (manufacturer) x quantity 


YF-12(NIKKO) x 1 


###■ 


Max. amperage 


3A 


### 


Flasher relay 






Relay type 


Full-transistor 


### 


Moctel (manufacturer) 


FE246BH (DENSO) 


##• 


Self-cancelling device built-in 


No 


### 


Turn signal blinking frequency 


75 ~ 95 cycles/min. 


• •• 




27 W x 2 + 3.4 W 


### 


Oil level switch model (manufacturer) 


5EB (DENSO) 


■mmm 


Fuel sender 






Model (manufacturer) 


1UF (NIPPON SEIKI) 


### 


Resistance 


0.7 ~ 1.1 kJ2GW-B 


### 


Sidestand relay 






Model 


G8R-30Y-K 


### 


Coil resistance 


162 - 198 £2 


### 


Fyei pump maximum amperage 


1 A 


### 


Fuel pump relay model (manufacturer) 


G8R-30Y-K (OMRON) 


### 


Resistance 


182 ■ 198Q 




Radiator fan model (manufacturer) 


4XV (TOYO RADIATOR) 


### 


Thermo switch model (manufacturer) 


5EB (NIPPON THERMOSTAT) 


mm® 


Headlight relay (manufacturer) 


ACA1 21 15 (MATSUSHITA) 


### 


Resistance 


72 - 88 Q 





2-18 



ELECTRICAL SPECIFICATIONS 



SPEC 



item 


Standard 


Limit 


Temperature sender 

Model (manufacturer) 
Resistance 


11H (NIPPON SEIKI) 

50.6 64.2 ft at 80°C (176°F) 

16.1 ~ 17.3 Q at 120°C (248° F) 




fyj.es (afiipetagc quantity) 

Main fuse 
Headlight fuse 
Signaling system fuse 
Ignition fuse 
Radiator fan fuse 
Backup fuse (odometer) 


30 A x 1 

20 A x 1 
20 A x 1 

15 A x 1 

7.5 A x 1 
7.5 A x 1 





2-1 ; 



CONVERSION TABLE/TIGHTENING TORQUES 



SPEC 



CONVERSION TABLE 

All specification data in this manual are 

listed in SI and METRIC UNITS, 

Use this table to convert METRIC unit data 

to IMPERIAL unit data, 

Ex. 



METRIC MULTIPLIER 

"mm x 0,03937 
i x 0.03937 

CONVERSION TABLE, 



IMPERIAL, 

"in 

0.08 in 



METRIC TO IMPER 


1 Metric unit 1 Multiplier Imperial unit 

Tiqhten- 1 m4;g 1 7 ' 233 fWb 
,'» j rrrkg 1 86,794 irrlb 

toque cm ' fe S I 0.0723 1Mb 
l0,i,UL cm»kg irrlb 


Weiqh, 1 kg | 2.205 lb 
y j 0,03527 J oz 


Speed j km/hr j 0.8214 j mph 

j km j 0.8214 mi 
I m 3,281 ft 
Distance j m i 1,094 yd 
j cm I 0,3937 in 
| mm I 0.03937 in 


| cc (errs 3 } I 0,03527 oz (IMP liq.) 
Volume/ I cc (cm 3 ) I 0.06102 cu»in 
Capacity I It (liter) 0.8799 qt (IMP liq.) 

! it (liter) j 0.2199 gal (IMP liq.) 

55 qo 7 I lb/in 

Wise I kg /cm- ) 14 ?234 P SI ( |b/in ^) 
" ' [ Centigrade 1 Q/r " X,,, Fahrenheit 
' • < 1 }''"'' ,s *' 1 i IT 



TIGHTENING TORQUES 

GENERAL TIGHTENING TORQUES 

This chart specifies tightening torques for standard 
fasteners with a standard ISO thread pitch. Tighten- 
ing torque specifications for special components or 
assemblies are provided for each chapter of this 
manual. To avoid warpage, tighten multi-fastener 
assemblies in a crisscross pattern and progressive 
stages until the specified tightening torque is 
reached. Unless otherwise specified, tightening 
torque specifications require clean, dry threads. 
Components should be at room temperature. 




A: Width across fiats 
Bi Thread diameter 



A 
(nut) 


B 
(bolt) 


General tightening 

torques 


Nm 


m«kcj 


fWh 


10 mm 


6 mm 


6 




4.3 


i 


H mm 


15 


1.5 


11 


14 mm 


10 mm 


30 


3.0 


22 




12 mm 


55 


5.5 


40 


Id mm 


14 mm 




8.5 


61 


dd Tint 




130 


13.0 


94 



2-18 



TIGHTENING TORQUES 



SPEC 



ENGINE TIGHTENING TORQUES 









„^_^_ 


ghtenir 


! Q 


Item 


Fastener 


Thread 
size 


Q'ty 


torque 


j Remarks 








J Nm 


m*kg 


ft»lt3 [ 







M10 


4 I 13 


1 .3 


~a4" | 


Cylinder head 


Bolt 


MIC) 


10 51 


5,1 


37 -a 


Cylinder head 


Bolt 


ye 


2 10 


1 .0 


"7 O 


Camshaft caps 


Bolt 


ye 


20 10 


1 .0 


72 -O 


Cylinder head cover 


Bolt 


M6 


6 1 


1 .0 


7.2 


Oil passage check bolt 


Bolt 


M8 


1 20 




1 4 ! 


Cylinder head (exhaust pipe) 


Stud bolt 


M8 


8 J 15 


1.5 


11 <3 


Connecting rod caps 


Nut 


yy 


See NOTE 


-«>.<»t 


Generator rotor 


Bolt 


M12 


1 1 65 


6.5 


47 <2 


Pickup rotor 


Bolt 


M8 


1 | 35 


" 


25 --Q 


Cap bolt (timing chain tensioner) 


Bolt 


M6 


1 1 10 


1.0 


_ « 


Timing chain tensioner bolt 


Bolt 


M6 


2 "12 


i O" 


8.7 


Camshaft sprocket 


Bolt 


M7 


4 24 


2,4 


17 | 


Oil pump 


Bolt 


M6 


3 J 12 


1,2 


o, / 


Oil cooler 


Bolt 


M20 


1 | 83 


8,3 


46 -*Q 


Engine oil drain bolt 


_ 


M14 


1 I 43 


A O 


31 


Oil pump assembly driven sprocket 


Bolt 


M6 


2 J 10 


1.0 


7.2 <I 


Oil pipe 


Bolt 


M8 


2 15 


1 c s 


11 <3 


Oil filter bolt 


Bolt 


M20 


t 80 


8.0 


58 


Oil filter cartridge 


- 


M20 


1 17 


1,7 


12 I -<3 


Exhaust pipes 


Not 


M8 


8 20 


2.0 


14 1 


Muffler clamp 


Bolt 


M8 


1 20 


2.0 


1 4 


Exhaust pipe emission check bolts 


Bolt 


Me 


4 10 


1 .0 


/ »c j 


Exhaust pipe bracket 


Bolt 


m& 


1 20 


2.0 


1 4 


Crankcase 


Bolt 


ye 


2 14 


1.4 


10 i -<3 


Crankcase 


Bolt 


M6 


12 | 12 


1.2 


8,7 I <J 


Crankcase 


Boit 


M8 


12 24 


r "i A 


17 | -a 


Generator rotor cover 


Bolt 


ye 


9 12 


1.2 


8,/ I 


Drive; sprocket cover 


Bolt 


ye 


5 | 10 


1.0 





NOTE; _______ 



After tightening to 15 Nm (1.5 m»kg, 11 ft»lb), tighten another 90 



2-19 



TIGHTENING TORQUES 



SPEC 



~~~~~~~~~~~~~~~\ 


Thread 
size 


I Tightening 




Item 


Fastener 


Q'ty 




torque 




Remarks 








Nin 


m»kq 


"fWb" 




Clutch cover 


Bolt 


M6 


10 ] 


12 


1.2 


8,7 




Pickup coil rotor cover 


Bolt 


M6 


5 


12 


1.2 


8.7 




Shift shaft cover 


Bolt 


M6 


6 


12 


1.2 


8.7 




Breather plate 2 


... 


M6 


3 


12 


1.2 


8.7 


<3 


Starter clutch 


Bolt 


M8 


3 


32 


3.2 


23 


<J 


Clutch boss 


Nut 


M20 


1 


70 


7.0 


51 


Use a lock 
washer. 


Clutch springs 


Bolt 


M6 


8 


8 


0.8 


5.8 




Drive? sprocket 


Nut 


M18 


1 


70 


7.0 


51 


Use a lock 
washer. 


Main axle bearing housing 


Screw 


M6 


3 




1.2 


8.7 


<3 


Shift bar stopper 


Boit 


Me 


2 




1.0 


™7 r^ 


O 


Shift shaft spring stopper 


Bolt 


M8 


1 




2,2 




<J 


Shift rod lockout 


Nut 


M8 
M8 


1 
1 


y 


0,7 
1.0 






Oil level switch 


Bolt 


M8 


2 


to 


1.0 


7.2 




Shift arm 


Bolt 


M6 


1 




1.0 


7.2 




Stator coil 


Boit 


M6 


3 




1.0 


7.2 


^C3 


Ignitor unit 


Bolt 


M6 


1 




1.0 


7.2 




Neutral switch 


Screw 


M6 


2 




0.4 


2.9 




Pickup coil 


Bolt 


M5 


2 




1.0 


7.2 


<3 


Thermo unit 




PT1/8 


i 


15 


1.5 


11 




rmo switch 




M18 x 1.5 


1 


28 


2.8 


20 





2-20 



TIGHTENING TORQUES 




ankcase tightening sequenc 



J P % V K P , tf '•'* &;) 

I , tf ' : ' W I % Yf ' to ' ~© , "' 
If,, , ,„. ,JJ - ;f;;' ', >*; | 






2-21 



TIGHTENING TORQUES 



SPEC 



CHASSIS TIGHTENING TORQUES 







Tightening 




Item 


sad size 




torque 


Remarks 


~Nm " 


m»kg 


!t*ln 


Upper bracket pinch bolts 


_ _ _ _ 


_ , 

28 


23 


19 




Steering stern nut 


M28 


115 


11.5 


83 




Handlebar pinch bolts 


M8 


33 


3.3 


24 




Lower ring nut 


M30 


9 


0.9 


6.5 


See NOTE. 


Lower bracket pinch bolts 


M8 


jU™W 


2.3 


17 




Brake fluid reservoir cap stopper 


M4 


12 


1.2 


8.7 




Front brake hose union bolts 


MIC) 


30 


3.0 


22 




Front brake master cylinder 


M6 


13 


1.3 


9.4 




Engine mounting 












Front mounting bolts 


M12 
M12 


K 


c c 


40 




Rear mounting bolts 


M10 








-a 


Pinch bolts 


M8 
M8 










Button head bolt 


M1C5 










Exhaust pipe bracket 


M8 










Pivot shaft: nut 


M18 










Connecting arms 


M10 










Relay arm and connecting arms 


M10 










Relay arm 


M10 










Rear shock absorber and relay arm 


M10 










Fuel cock 


M6 










Fuel sender and fuel tank 


M6 










Coolant reservoir and radiator 


ye 










Rider footrest bracket 


mb 










Passenger footrest bracket 


M8 










Rear master cylinder 


M8 










Rear brake hose union bolts 


M10 










Sidestand 


M10 










Front wheel axle 


M18 


72 


7.2 


52 




Rear wheel axle nut 


M24 


150 


15,0 


108 




Front brake? caliper and front fork 


M10 


40 


4,0 


29 




Rear brake caliper and bracket 


M10 


27 


2,7 


20 




Brake disc and wheel 


ye 


18 


1.8 


13 




Rear wheel sprocket and rear wheel drive hub 


M10 


69 


6,0 


50 




Brate caliper and bleed screw 


M8 


6 


0,6 


4,3 




Pinch bolt (front wheel axle) 


M8 


23 


2.3 


17 





NOTE: _____^^^ 

1 . First, tighten the ring nut to approximately 17 Nm 
loosen the ring nut completely. 

2. Retighten the ring nut to specification. 



1 .7 m»kg, 12 ft«lb) with a torque wrench, then 



2-22 



LUBRICATION POINTS AND LUBRICANT TYPES 



SPEC 



LUBRICATION POINTS AND LUBRICANT TYPES 

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 



Lubrication point nicant 


Oli ',< ,il i'j , J Hi<s»f 


ings 


-*•»§ 


Bearings 


-Q 


inkshaft pins 


, -«J 


Piston surfaces 


-Q 


Piston pins 


-G 


meeting rod bolts and nuts 




.nkshaft journals 


-O 


Camshaft lobes 


-0 


Camshaft journals 


Valve sterns (intake and exhaust) 


— <3 


Valve stern ends (intake and exhaust) 


-Q 


Water pump impeller shaft 


-Q 


Oil pump rotors (inner and outer) 




housing 


-Q 


Oil strainer 


-«Q 


Starter' clutch idle gear inner surface 


-Q 


Starter clutch assembly 


-Q 


Primary driven gear 


-O 


tission gears (wheel and pinion) 


~"~"^ImI 


Main axle and drive axle 


— — <^^ 


Shift drum 


-d 


Shift forks and shift fork guide bars 


-O 


Shift shaft 


-Q 


Shift shaft boss 


-«.'»t 


Engine mounting bolts (rear) 


-*•*% 


Cylinder head cover mating surface 


Yamaha bond 
No. 121 5 


Crankcase mating surface 


Yamaha bond 


Clutch cover (crankcase mating surface) 


Yamaha bond 
No, 121 5 


Generator rotor cover (crankcase mating surface) 


Yamaha bond 
No. 121 5 


Cylinder head cover 


Yamaha bond 
No. 121 5 



2-23 



LUBRICATION POINTS AND LUBRICANT TYPES 



SPEC 



CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 



ubrication 


Lubricant 


J bearing races (upper and lower) 


r - „. 


Front wheel oil seal (right and left) 


r -**t 


Rear wheel oil seal 


-Ht*| 


Rear wheel drive hub oil sea! 


-*•■* 


Rear wheel drive hub mating surface 


-•♦1 


Rear brake pedal 


1 -a** 


Sidestand pivoting point and metal-to-metal moving parts 


-V»f 


Throttle grip inner surface 


-««■* 


Brake lever pivoting point arid metal-to-metal moving parts 


-««* 


Clutch lever pivoting point and metal-to-metal moving parts 


-fr«* 


Rear shock absorber assembly oil seal 


-»•»! 


Rear shock absorber assembly bearing 


-»*§ 


Rear shock absorber assembly spacer 


-•••t 


Pivot shaft 


-*>Ȥ 


Connecting arm bearii 


-ntc*n 


Spacer (relay arm and connecting arm) 


-C<s»f 


Oil seal (relay arm and conne 


-c»t 



2-24 



OIL FLOW DIAGRAMS 



iaft 



OIL FLOW DIAGRAMS 



SPEC 



_J 



m 




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OIL FLOW DIAGRAMS 



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OIL FLOW DIAGRAMS 



SPEC 



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2-27 



OIL FLOW DIAGRAMS 



SPEC 



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COOLANT FLOW DIAGRAiS 



COOLANT FLOW DIAGRAMS 



or 

or fan 
>ler 



SPEC 



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COOLANT FLOW DIAGRAMS 



SPEC! O"* 



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2-30 



(1„) Radiator cap 
(2) Radiator 
cooler 

iter Jacket joint 
(5) Water pump 



COOLANT FLOW DIAGRAMS I SPEC 



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13) 



,1) Radiator' 

diator fan switch 

'3) Radiator fan 



COOLANT FLOW DIAGRAMS 



SPEC 



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CABLE ROUTING 



? rattle cables 
brake hose 
(|) Clutch cable 
arter cable 

' switch lead 
(> Main switch lead 



I 



CABLE ROUTING 



SPEC 



lJ3 Install the) headlight relays onto the) headlight housing bridge. 

)ute the headlight lead through the plastic guide. 
[Cj Route the right handlebar switch lead in front of the front fork inner 
tube. 

>ute the wire harness through under the left handlebar switch lead 
and starter cable. 
[El Fasten the left handlebar switch lead to the front fork with a plastic 
^__ locking tie and cut the end of locking tie. 

isten the throttle cables and starter cable with a band. 
Locate the end of band to forward. 



k ' . |» > - 



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2-33 



CABLE ROUTING 



Dute the horn lead outside the throttle cables and 
fasten it to the under bracket with a plastic locking 
tie. Cut the end of locking tie. And then, route the 
horn lead under the brake hose and clamp it to the 
under cover, 
[HJ Route the throttle cables between the brake hose 
and right handlebar .switch lead. 



SPEC 



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CABLE ROUTING 



SPEC 



fead 



[A] Route the ignition coil lead and thermo switch lead 
over the heat protector plate, 

on the face of steel clip up ward. 
jCj Route the clutch cable through the guide on the 
frame. 

oute the coolant hose under the heat protector 
plate. 



S E] Fasten the clutch cable to the coolant hose protec- 
tor with a plastic band. 

lEj Fasten the rear brake switch lead to the footrest 
bracket with a plastic locking tie) arid cut the end of 
locking tie. 

[G] Fasten the fuel pump lead and rear brake switch 
lead with a plastic band on the fuel pump bracket. 




k. 



\ 




2-35 



CABLE ROUTING 



SPEC 



(j ,,) Oil lever switch lead 

(2) Sidestand switch lead 

(3) Reservoir tank breather hose 

(4) AC magneto lead 

,1 switch lead 
el pump lead 
■eed sensor lead 
[A] Route the throttle cable through inside of the radia- 
tor bracket and outside of the wireharness. 
[Bj Fasten the wireharness, radiator hose and fan mo- 
tor lead with a plastic band, 
G Do not touch the wireharness with the throttle cable 
pully. 
Route? the wireharness under the radiator hose. 



Mi- 



ld] Pass the fuel tank drain hose and the fuel tank 
breather hose should between the reservoir thank 
breather hose and the coolant breather hose, and 

kept outside the leads, 
|j| Route the wireharness through the siit of rear fender, 
[Fj Pass the fuel tank drain hose and the fuel tank 

breather hose inside the curved under cowling, 
16) Put the fuel tank drain hose and fuel tank breather 

hose into the reservoir tank by passing through the 

tank holder. 

No fixed order required, 

Do not twist the hoses. 
[H] Put the fuel tank drain hose and the fuel tank 

breather hose through the hook and the side 

stand's holder. 

No fixed order required. 

Do not twist the hoses. 




2-38 



CABLE ROUTING 



SPEC 



When the sidestand is clown, [O] Route the rear turn signal light leads (left and right) 

The end of the drain hose must be located in through the hole of rear fender. 



between. 

i the sidestand switch lead and oil level sen- 
sor lead with a band. 

[Lj Route the fuel tank drain hose, fuel tank breather 
hose, reservoir tank breather hose;, oil level switch 
lead and sidestand switch lead through the guide 
on the frame. 

[ivf Route the starter cable between the main switch 
lead and left handlebar switch lead. 
mite the seat lock cable outside of the wirehar- 




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2-37 



(1) Throttle cable 

(2) Handlebar switch lead (right) 

(3) Coolant temperature sensor lead 

(4) Coolant reservoir breather hose 

le adjust screw 
3kup coil connector 
i Neutral switch connector 

jar brake switch connector 
(|) Handlebar switch (right) connec- 
tors 
i> ' Throttle position sensor connector 
ain switch connectors 
mdlebar switch (left) connec- 
tors 
(ill Neutral switch lead 
(14) Fuel pump connector 
(I'Si Rear brake switch lead 




CABLE ROUTING 

■ Starter motor lead 

> Battery negative (-) cable 
i Fuel sender connector 

> Crankcase breather hose 
Coolant reservoir tank cap 
Heat protector 

Fan motor lead connector 
Clutch cable 

Handlebar switch lead (left) 
Starter cable 
Main switch lead 



adlight lead 

LB] Route the clutch cable through the guide. 



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SPEC 



|Cj Fasten the handlebar switch leads (left and right) 
and main switch lead with a band, 

|Dj Route the ignition coil lead and handlebar switch 
leads (left and right) over the heat protection plate. 

[Ej Route the reservoir tank hose, carburetor heater 
hoses under the heat protector plate. 

Ill) Route the coolant temperature lead upper the heat 
protection plate. 

[Gj Route the coolant breather hose upper the heat 
protection plate. 

[R] Fasten the neutral switch lead, right handlebar 
switch lead, main switch lead, TPS lead, left han- 
dlebar switch lead, pickup coil lead and main har- 
ness with a band. 



L Li Insert the projection of the band to the hole of the 

frame and fasten the wireharness, neutral switch 

lead, handlebar switch leads (left and right), main 
switch lead, throttle? position sensor lead, rear 
brake switch lead and pickup coil lead with them. 

I jj Route the starter motor lead under the wirehar- 
ness. 

IKJ Fasten the starter motor to the rear fender with a 
band. 

[LI Fasten the battery positive (+) cable and starter 
motor cable with a plastic band. 

!M! Position the rear turn signal light connectors (left 
and right) and taillight connector between the rear 
fender and taillight bracket. 

stall the seat lock cable to the frame bracket with 
protector side. 



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CABLE ROUTING 



SPEC 



2 battery negative lead after passing un- 
iin harness and oil level sensor lead, 
} main harness, oil level sensor lead and 
id with a band. 

i starter relay lead and battery negative 
the wirehamess with a plastic band, 

5 battery negative (-) lead and wirehar- 

a plastic band, 

Drojection of the band (wirehamess) into 

f the frame, 

sensor connector 

gneto connector 
switch connector 
4; Oil levei switch connector 
5: Meter around lead 



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[V] The fuel tank drain hose, coolant temperature lead 
and the coolant breather hose must be located 

__ over the groove?. 

[W| Fasten the leads (above 1 - 5) and starter motor 
lead with a steel band on the engine. 

[X] Route the coolant breather hose upper the main 
harness. 

! Y] Route the fuel tank breather hose and fuel tank 

_ drain hose over the wirehamess. 

jZj To carburetor 

A'j The starter cable must not be out off the guide 
j of the cover. 

[Bl Route the starter cable upper the heat protec- 
tion plate. 
»ert the starter cable to the guide. 
fan motor 

E" Route the starter cable and main harness through 
the guide of the heat protection plate. 



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-40 



CHK | 
, ADJ | 

CHAPTER 3. 
PERIODIC CHECKS AND ADJUSTMENTS 

INTRODUCTION , , , , , . 3.1 

PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL 

SYSTEM 3-1 

GENERAL MAINTENANCE AND LUBRICATION CHART .......... 3-2 

RIDER AND PASSENGER SEATS 3-3 

FUEL TANK 3.4 

COWLINGS 3-5 

REMOVAL 3.7 

INSTALLATION , 3-7 

AIR FILTER CASE AND IGNITION COILS , 3-8 

REMOVAL 3-10 

I LATION . ...,,,., . 3-10 

ENGINE ., , 3.11 

ADJUSTING THE VALVE CLEARANCE 3-11 

SYNCHRONIZING THE CARBURETORS 3-16 

ADJUSTING THE ENGINE IDLING SPEED 3-18 

ADJUSTING THE THROTTLE CABLE FREE PLAY 3-20 

CHECKING THE SPARK PLUGS 3-22 

CHECKING THE IGNITION TIMING , 3-23 

MEASURING THE COMPRESSION PRESSURE 3-24 

CHECKING THE ENGINE OIL LEVEL . , , 3-26 

CHANGING THE ENGINE OIL 3-27 

MEASURING THE ENGINE OIL PRESSURE 3-29 

ADJUSTING THE CLUTCH CABLE FREE PLAY 3-30 

CLEANING THE AIR FILTER ELEMENT 3-31 

CHECKING THE CARBURETOR JOINTS 3-32 

CHECKING THE FUEL HOSES AND FUEL FILTER 3-32 

CHECKING THE CRANKCASE BREATHER HOSE 3-33 

CLEANING THE. AIR INTAKE SYSTEM 3-33 

CHECKING THE EXHAUST SYSTEM 3-34 

CHECKING THE COOLANT LEVEL 3-35 

CHECKING THE COOLING SYSTEM 3-35 

CHANGING THE COOLANT . . 3336 

CHASSIS 3-39 

ADJUSTING THE FRONT BRAKE 3-39 

ADJUSTING THE REAR BRAKE , 3-39 

CHECKING THE BRAKE FLUID LEVEL 3-41 

CHECKING THE BRAKE PADS 3.42 



<& 



CHK 
ADJ , 

ADJUSTING THE REAR BRAKE LIGHT SWITCH ............... 3-42 

CHECKING THE BRAKE HOSES 3-43 

BLEEDING THE HYDRAULIC BRAKE SYSTEM . , . 3-43 

ADJUSTING THE SHIFT PEDAL 3-45 

ADJUSTING THE DRIVE CHAIN SLACK 3-45 

LUBRICATING THE DRIVE CHAIN 3-47 

CHECKING AND ADJUSTING THE STEERING HEAD 3-47 

CHECKING THE FRONT F'ORK 3-50 

ADJUSTING THE FRONT F'ORK LEGS . . , , , 3-51 

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-54 

CHECKING THE TIRES 3-57 

CHECKING THE WHEELS 3-59 

CHECKING AND LUBRICATING THE CABLES . . . 3-60 

LUBRICATING THE LEVERS AND PEDALS 3-80 

LUBRICATING THE SIDESTAND . 3-60 

LUBRICATING THE REAR SUSPENSION , 3-80 

ELECTRICAL SYSTEM , 3-61 

CHECKING AND CHARGING THE- BATTERY 3-61 

CHECKING THE FUSES . 3-86 

REPLACING THE HEADLIGHT BULBS , 3-63 

ADJUSTING THE HEADLIGHT BEAMS . 3-69 



M 



INTRODUCTION/PERIODIC MAINTENANCE CHART FOR 

EMISSION CONTROL SYSTEM 



CHK 
ADJ 



<a 



PERIODIC CHECKS AND ADJUSTMENTS 
INTRODUCTION 

This chapter includes all information necessary to perform recommended checks and adjustments. If 
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a 
longer service life and reduce the need for costly overhaul work. This information applies to vehicles 
already in service as well as to new vehicles that are being prepared for sale. Aii service technicians 
should be familiar with this entire chapter, 



PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM 


No. 






1N)T|A1 ~~ y— — — — — — — ^^ 




ITEM 


ROUTINE 


800 mi j 4,000 mi 
{1,000 km) (7,000 km) 

Of ! or 
1 month 8 months 


8,000 mi 
(13,000 ton) 

or 
12 months 


1 2,000 mi 

(19,000 tan) 

or 
18 months 


18,000 mi 
(25,000 km 

24 months 


20,000 mi 
{'31,000 km) 

30 months 


1 


v , . , h ,,_ ;-i r> • Check and adjust valve clearance when 


Every 26,800 mi (42,000 km) 


», I 




« Check condition . 

• Replace at 8,000 mi (13.000 km) or 
12 months and thereafter every 8.000 mi 
(12,000 km) or 12 months. 






Replace 


™ 


Replace 


< 


1 


system 


« Check ventilation hose for cracks or damage. 








' 






4 ' 




• Check fuel hose tor cracks or damage. 














5 1* 


.... 


• Replace initial 20.000 mi (31,000 km) and 
thereafter crvery 20,000 mi 031 ,000 krro 












Replace 


6 j- 




« Retighten if necessary. 

« Replace gasket(s) il necessary. 














7 * 
1 i 


Synchronization 


•Adjust synchronization of carburetors. j 


I r [ \ I ". j \ | 

_ . j „ , I I I I 


8 [ " 1 




• Check and adjust engine idle speed. 1 

• Adjust throttie cable free play, | 


I >. i \ ■■ I . ! 


9 j • J 


' '■■ i 


• Check control system for damage. I 


| V j 




: 



Since these items require special tools, data, and technical skills, they should be serviced by a Ya- 
maha dealer. 
" California only. 



3-1 



GENERAL MAINTENANCE AND LUBRICATION CHART 



CHK 
ADJ 



<& 



GENERAL MAINTENANCE AND LUBRICATION CHART 






INITIAL 


ODOMETER READINGS 


No. 


ITEM ROUTINE 


800 mi 
(1,000 km} 

or 
1 month 


4,000 mi 

(7,000 ton) 

or 

8 months 


8,000 mi 
(13,000 km) 

or 
12 months 


12,000 mi 18,000 mi j 20,000 mi 
(19,000 km) (25,000 km) (31,000 km) 

or cm' or 
18 months 24 months 30 months 


11 Engine oil » Replace. Warm engine before draining. 1 
|_ J_.| ; _ _1 _ ;_. , , _ _ J ..' _ 


V 


v 




• Replace at 600 mi H .000 km) or 1 month, 
2 " Engine cxI After 




\ 




I 


v 


\ 


' 








■■ 




I 




...o,i.« ; , „y.,.t. 

• Ethylene glycol anti-freeze coolant. 








Replace 


I I • CI' fluid 
5 I * J Brake system NOTE.) 

... Jj _ „ , _ 


'• : 


V 


v 


~" " " j~ ~ ' 

| 






h 


V 


v 


V 


• 


V 


I I r „„ ,| * Apply chain lube thoroughly. 

7 • :;,;;' • Yamaha chain and cable lube or SAE 10 W 30 

I ■■•''-"• motor oil 


si 


'V 


', 


'> 


V 




I | J • Check bearing assembly (or looseness 
j. Swing arm pivot • Moderately repack everv 16.000 mi 

I be3rm9 

I | * LufHurn soap oase grgs.se. 






• 




Repack 




« L I Rear suspension link * Check operation. 

.: M.P2^._ _ _ _ _ 






V 




■ 




10 1- Rear shook absorber | ^«* ^ratoandoil leakage. 




■• 


\ 


-■ 




\l 


11 ' J Front fork * 




•< 


V 


- 


V 


- 


I I • Check bearinq assembly for looseness 

1 i 
12]* Steering bearings j • Moderately repack every 16,000 mi 

I | (24,000 km) 

j j • Lithum soap base grease. 




< 


^ 


V 


Repack 


"V 


I j n r ,|,,, irt.nrh irvo- • Apply chain lube lightly. 
13 I j -" • Yamaha chain and cable lube or SAE 10 W 30 
j i ''" "' *' motor oil. 




h 


V 


■>; 




■ 


Brako pedal and ' A PP'V chain lube "9^- 
14 [ « Yamaha chain and cable lube or SAE 10 W 30 




V 


' 


V 


V 


V 


I 1 « Check chain slack/ aliqnment condition. 
15 M Drive chain • Adjust and lubricate chain throughly. 


Every 600 mi (1,000 to) arid after washing the 
motorcycle or riding in the rain 


16 




\ 


\ 


V 


V 


V 


17 | | ; = l!jes,ana P'vot > Yamaha chain and cable lube or SAE 10 W 30 

motor oil 




'- 





V 


- 


• 


-„ l.i ,,., , , .,", t ",,,""", " ,~ , — ', ", i " : ! ; " I — i~ r - ~ — " T ~ — — ~ 

18 Sides and switch « Check and clean or replace it necessary. \ -,, \ v I 

L L . L _ _ _ '__ L _ .J- U — 4- - I — - t — 


- j • I h ~\ r, | . 



* Since these items require special tools, data and technical skills, they should be serviced by a Ya- 
maha dealer, 
NOTE; ^^___^^ 

For odometer readings or time periods higher than 20,(300 mi (31 ,000 km) or 30 months, repeat the 
same maintenance as listed in the chart from the 4,000 mi (7,000 km) or 8 months interval. 



NOTE: _______^ 

•The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 
• Hydraulic brake system 

• When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Cheek 
the brake fluid level reqularly and fill as required, 

• Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years. 

• Replace the brake hoses every four years or if cracked or damaged, 



3-2 



RIDER AND PASSENGER SEATS 






RIDER AND PASSENGER SEATS 



5 



1 


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kg, 5.1 fMb) 




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Order 



1 

2 



Job/ Part 



Removing the rider and passenger 
seats 

Passenger seat 
Rider seat 



Q'ty 



Remarks 



Remove the parts in the order listed. 



For installation, reverse the removal 
procedure. 



3-3 



FUEL TANK 




FUEL TANK 



33 ONp!J 1 ]5^i<g?7i , 'i»ib)] 



<Si^^J>J\, 







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Order 



2 
3 
4 



5 
6 

7 



Job/ Part 



RetnoYJng the fuel tank 

Rider seat 
Bolt 

Bolts 

Fuel sender coupler 

Fuel hose 



Fuel tank overflow hose 
Fuel tank breather hose 
Fuel tank 



1 

2 
1 
1 



Remarks 



Remove the parts in the order listed 
Refer to "SEATS", 



Disconnect. 

NOTE: ____________^ 

Before disconnecting the fuel hose, set 
the fuel cock "OFF", 



For installation reverse the removal 
procedure. 



3-4 



COWLINGS 



CHK 
ADJ 



<$t 



COWLINGS 



10 



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rvni 



I 5 N m (0.5 m» kg, 3.6 fMb) 



J % Ni?t (0 5 ni-kg. 3 6 fMb) 



Order j Job/Part 


Q'ty 


Remarks 


| Removing the cowlings 
Rider and passenger seats 

1 Rear cowling 

2 Bottom cowling (left) 

3 1 Bottom cowling (right) 

4 Front cowling inner panel (left) 

5 Front cowling inner panel (right) 

6 Side cowling inner panel (left) 

7 Side cowling inner panel (right) 




Remove the parts in the order listed 
Refer to "SEATS", 



3-5 



COWLINGS 



COWLINGS 



ADJ \W 



11 



10 



11 



i 



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Order 


Job/ Part 


Q'ty 


Remarks 


8 
9 
10 


Left side cowling 
Flight side cowling 
Windshield 


1 
1 
1 




11 


Rear view mirror 


2 




12 


Front cowling 


1 


For installation, reverse the removal 








procedure. 



COWLINGS 




CHK 

adj" 



<a 



REMOVAL 

1, Remove: 
• rear cowling 
•side cowlings 

NOTE: _____ 



To remove the quick fastener, turn its center to 
90° with a screwdriver, then pull the fastener 
out. 



INSTALLATION 

1, Install: 
•side cowlings 
• rear cowling 

NOTE; _____ 



To install the quick fastener, push its pin so that 
it protrudes from the fastener head, then insert 

the fastener into the cowling and push the pin® 
in with a screwdriver. Make sure that the pin is 

flush with the fastener's head. 



3-7 



AIR FILTER CASE AND IGNITION COILS 



CHK 
'AD J 



<$t 



AIR FILTER CASE AND IGNITION COILS 



1^ ? 



10 



' Vt 



id 



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Order 


Job/ Part 


Q'ty 


Remarks 




Remowing the air filter case and 




Remove the parts in the order listed, 




Ignition coils 








Rider seat and fuel tank 




Refer to "SEATS" and "FUEL TANK", 




Front cowling inner panel (left) 




Refer to "COWLINGS". 




Front cowling inner panel (right) 






1 


Crankcase breather hose 


1 




2 


Air vent hose 


1 




3 


Hoses 


2 




4 


Drain cup 


1 




5 


Air filter case balance hose 


2 




6 


Clamp screw 


4 


Loosen, 


7 


Bolt 


1 




8 


Surge tank joint (left) 


1 




9 


Surge tank joint (right) 


1 




10 


Air filter case 


1 




11 


Clamp 


2 




hi 


Quick fastener 


•J 





3-8 



AIR FILTER CASE AND IGNITION COILS 



CHK i 101 
ADJ i Ht 




Order 


1 

I _ _ 


Job/ Part 


Q'ty 


Remarks 


13 


Heat protectc 


r plate 


1 




14 
15 


1 Ignition coil c 
Ignition coil 


oupler 


4 
4 


For installation, reverse the removal 
procedure. 



3-9 



AIR FILTER CASE AND IGNITION COIL PLATE 



CHK 
ADJ 



<$t 




REMOVAL 
1. Remove! 
• heat protector plate 

NOTE: _____^^^ 

To remove the quick fastener, push its center in 

with a screwdriver, then pull the fastener out. 



INSTALLATION 
1. install; 
• heat protector plate 

NOTE; _______ 



To install the quick fastener, push its pin so that 
it protrudes from the fastener head, then insert 
the fastener into the rubber baffle and push the 
pin (a) in with a screwdriver, Make? sure that the 
pin is flush with the fastener's head. 



3-10 



ADJUSTING THE VALVE CLEARANCE 



CHK I |0| 



ENGINE 

ADJUSTING THE VALVE CLEARANCE 

The following procedure applies to all of the 
valves, 

NOTE: ~^^__^^ 

• Valve clearance adjustment should be made 
on a cold engine, at room temperature. 

•When the valve clearance is to be measured 
or adjusted, the) piston must be at top dead 

center (TDC) on the compression stroke. 

1, Remove: 

• rider seal 

• fuel tank 

Refer to "SEATS" and "FUEL TANK", 
•air filter case 

• heat protector plate 

Refer to "AIR FILTER CASE AND IGNITION 
COILS". 

• bottom cowling 

• side cowlings 

Refer to "COWLINGS", 
•carburetor assembly 
Refer to "CARBURETORS" in chapter 6. 

• radiator assembly 

Refer to "RADIATOR" in chapter 5. 






X MVOl h 



2. Remove: 

• ignition coils 
•spark plugs 
•cylinder head cover (1) 

• cylinder head cover gasket 





1 if^ w 


/JO 1 

atv~ 1 






fe=2@ © f§ 


WH-A 


1 
/ i 




L ) ' 


! |1\ / // 




\ \ J l - JS *j" t-.;r 


/0*®T - 


---OOT'O^ 7 





3. Remove: 
• pickup coil rotor 



3-11 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 



<$t 



b " v W : 

-'Z,^7 J7b~K 



EX 



IN 



'vljV 



WM 



I -^ , (f 

1 /V'-^C-. /V<"" - , \ V x" 

,- -.''VO. 



--»• 



_ ; i x 

#1 #2 #3 #4 




j 




4, Measure: 

• valve clearance 
Out of specification ► Adjust 




Valve clearance (cold) 

Intake valve 

0.11 ~ §.20 mm 
(0,0043 - 0.0079 in) 

Exhaust valve 

§.21 - 0.30 mm 

(0.0083 •- 0.0118in) 



a. Turn the crankshaft clockwise, 

b. When piston #1 is at TDC on the compres- 
sion stroke, align the TDC mark (a) on the 
pickup coil rotor with the crankcase mating 

surface®, 

NOTE: _____^^ 

TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other, 

c. Measure the valve clearance with a thick- 
ness gauge CD- 

NOTE: ____^___^^ 

• If the valve clearance is incorrect, record the 
measured reading, 

• Measure the valve clearance in the following 

sequence. 



Valve clearance measuring sequence 
Cylinder #1 •-#2- + #4-* #3 



[S Front 

d. To measure the valve clearances of the other 
cylinders, starting with cylinder #1 at TDC, 
turn the crankshaft counterclockwise as spe- 
cified in the following table. 

Et Degrees that the crankshaft is turned counter- 
clockwise 

ICJ Cylinder 

[D] Combustion cycle 



Cylinder #2 


^_____^^ 


Cylinder #4 


360" 


Cylinder #3 


| 540° 



3-12 



ADJUSTING THE VALVE CLEARANCE 



CHK 
ADJ 



<& 



5, Remove: 
•timing chain tensioner 
•timing chain guide (exhaust side) 
•camshaft cap 
•timing chain 
(from the camshaft sprockets) 

• intake camshaft 

• exhaust camshaft 



NOTE; __^____^^ 

• Refer to "CAMSHAFTS" in chapter 4, 
•When removing the timing chain from cam- 
shafts, fasten the timing chain with a wire) to re- 
trieve it if it fails into the crankcase. 



' FX 


1 
o o 


2 3 4 

O OO GO Q 


/ IN 


ig^ || 


@ @|| jili @j 



lit 722(11 



:i4E 



8. Adjust: 
•valve clearance 



a. Remove the valve lifter (T) and the valve pad 

NOTE; ______^____^^ 

• Cover the timing chain opening with a rag to 
prevent the valve pad from falling into the 
crankcase. 

• Make a note of the position of each valve lifter 
(1) and valve pad (2) so that they can be 
installed in the correct place. 

b. Select the proper valve pad from the follow- 
ing table. 



Valve pad thick- 
ness range 


Available valve 
pads 


Nos. 

120 ~ 

240 


1.20 ~ 

2,40 mm 


25 thicknesses in 
0,05 mm incre- 
ments 



NOTE: _____^^ 

• The thickness (a) of each valve pad is marked 
in hundredths of millimeters on the side that 
touches the valve lifter. 

• Since valve pads of various sizes are originally 
installed, the valve pad number must be 
rounded in order to reach the closest equiva- 
lent to the original. 



3-13 



i THE ¥AL¥E CLEARANCE 


adj |Vf 




c. Round off the original valve pad number ac- 
cording to the following table. 




_____[_ 


Roynded walye 




0or2 | 







~~ 5 ~ ' 

, . _ _ __ _ _J 






8 1 





f 


V' \ Y \/k v 


\ (D 




. of 





EXAMPLE; 

Original valve pad number = 148 (thickness = 

1 .48 mm) 

Rounded value = 150 

d. Locate the rounded number of the original 
valve pad and the measured valve clearance 
in the valve pad selection table. The point 
where the column and row intersect is the 
new valve pad number. 

NOTE; _____^^ 

The new valve pad number is only an approxi- 
mation. The valve clearance must be measured 
again and the above steps should be repeated if 
the measurement is still incorrect. 

e. Install the new valve pad(T) and the valve lift- 
er®. 

NOTE: _____^^ 

• Lubricate the valve pad with molybdenum dis- 
ulfide grease. 

• Lubricate the valve lifter with molybdenum dis- 
ulfide oil. 

•The valve lifter" must turn smoothly when ro- 
tated by hand. 

• Install the valve lifter and the valve pad in the 
correct place. 

f. Install the exhaust and intake camshafts, 
timing chain and camshaft caps, 



___ 



Camshaft cap bolt 

10Nm(1.0m*kg,7.2fHb) 



NOTE: _______^^ 

• Refer to "CAMSHAFTS" in chapter 4. 
•Lubricate the camshaft lobes and camshaft 

journals. 

• First, install the exhaust camshaft. 

•Align the camshaft marks with the camshaft 

cap marks. 
•Turn the crankshaft counterclockwise several 

full turns to seat the parts. 



3-14 



ADJUSTING THE ¥AL¥E CLEARANCE 



CHK 
ADJ 



<$t 



¥AL¥E PAD SELECTION TABLE 
INTAKE 





~^~~*~*~~~^^ 




1 9'n 


1 30 


1 IT 


\m\M » 


165 

zzzzxz 


i 70 


™™~ 


180 


185 

—_- — ™, 


M 


.J95 


200 




PPI 






» ™._ 






1 20 


12^J.30pI5fliO 


145 


150 


155 


™"'-™ — 
160 


1035 


.170 


175 


1 _ 


ll 


1 90 


1951,200 






0,03 ,.07 






1 20' 


1 25 


J3ll35pii.!15 


m 


155 
160 


111 


185 


•— - 




7s"o 


185 






251205" 






lbs - o/io 




1 ?0 


125 


J30 


135 h< 


155 


165 


170 






185 


i§L_ 


1777 


200 


-: — = H 1 

205 210 










i's 


TANfMHI 


oct 


____ 




0.21 0.22 


125 


1 30 


135 


1 40 


11451150 

™»,™,™,.^^ B| m™,™, 


1SS 


160 


165 

— • 


*__™™™, 


___, 

— 


180 


785 




1.95 


POO 


205 


110 


"21 5 


__ 






"""117-0.27"*** 


Hi 


11 


Mi 


III 


I 'till liS 


160 


JJhl 


*™™™™™ 


j J^ 




i__. 


111 


__ 

JLHr, 


200 


ll 


III 




2 1 5 


220 








0,28 -■■■-' 0,32 


1 35 


140 


J45 


1 50 

— _. 




i§o 


_, 


izi 


175 


III 


ill 


J_90 


.195 




205 


210 


215 


220 


225 












J45 


1 50 


155 


Too" 


165 




175 


J80 


1 85 


190 


"195" 


200 


"-7-; "™ 

205 


_._ 


II 


220 


225 


230 






.^„J™J_™, ™„™i',i £:;■„„„ 




__. 




160 


1 65 


m 


J__L 


180 


,,i™i£ 


He. 


195 


H__ 


205 


2T0 


2l¥ 


220 


__ 


230 


HI 








JMlrJML 










770 


111 


1 30 


1 A^ 


190 


.1§5, 


200 




210 


215 


HI 


225 


230 


235 


240 






a 4G ft C9 


111 


Ill 


Ill 


1 70 





j«i 


~_2,. 


Jj__ 


jjI 


200 


205 


111 


illil 


220 


225 


230 


235* 


240 












1 70 




180" 


185 

_ 


190 

__ 




foo 


— — 


III 


215 


220 


— .- 


230 


235' 


240 










Ill 




Tso 


185 






200 




210 


215 


~™ — 

220 


8822 


230 


78" 








0.63 — 67 




IIP. 


in 


115 


Tio 


Ili 


200 


ire 


—J 


215 


220" 


__ 


230 


235(240! 






0,133 0.72 


1 75 


180 


185 


190 




200 


205 


210 


215 


220 


irrz"™ 


230 


__ 


240[ 






..■m™™,,™;,™,™.™™™,,™,™™,™^,™,™ 


III 




m 


I* 


2(5) 


w 


210 


215" 


220 


225 


230 










78 82 


1 85 
™~™~.™~ 


i 90 


195 


POO 


205 


210 


215 


22Q 


225" 


230 


205 


III 




Example: 




1QO' 


III 


m 


w 




Hi 


ff 


HE 


230 




IIS 




Valve Clearance (cold) 


0.88 ; 0.92 :i . 






205 


210 


215 


220 




230,. 


m 


11 




n 11 ,— . f) Of\ mm 


0.93 — 0.97 


200 


205 


?"10 


215, 


220 


III 


!» 




240 




D^. ««^.lrt^ **<"»!, «« 4rn 


___^_, 




c* "i n ^ 


215 


2M 


5r.,™8 


230, 


7 ™"i 


115] 




Huuiiuuu vcuuc 1 u\J 




210: 


111] 


# 


T\inr-i 


230 


"235": 


240 




Measured valve clearance is 0.24 mm 


1.08 1.12 i 


j£i.£,| 


220 j 




23C0 




240j 




Replace pad 150 with pad 160 


'1 -j 3 | '| j j 


2£0] 


™£™J 


230j 


iSsl 


240 




Pad No. 150 = 1.50 mm 


i 




230] 


~;~:i 


240J 




Par! Kin 1 fill — 1 ftA mm 




230 1 


235 


MP 






1 oa i qc> 1 




111 




Miw<ayt> inaiaii me vaive pau wim trie 




i_wZHll 


mm^mmm 






















nurnoer 1 


acing dowr 


. 







EXHAUST 





RIGIN/ 


vL W 


\LVE PAD NUMBER 


— — — 


M — 


«---»—<— 


— 


».J™_iL 


JI2 


=82= 


135 


140 


tJ# 


_150 




J80 


185 


170 

Iff 


Its 
Tso" 


780" 

1 55 


185 

j_80 


Jll 


w 


M 


205" 








11 
200 


205210 


240 

r 








— "-""- 




120 


III 




w 


165 


r 

170 


775 


__ 


J« 


M 


ft 


0.03 ■ 0.07 










180 


_ 


J30 


835 


140 


145 


150 








170 


' "JL 


"180 


___ 


190 




800 




277777215 




I 








"T20" 


.125 




1 35 


J 40 


ill 


150 
™ — 


iM, 


"ieo 




m 


177 


J2!l7 


Ili" 


777 


195 


200 


tm 


777*67 






O2T3" 0.77 








1 ^S 

™_„™„ 


130 


1M 


140 


145 




155 


mi 


H 


111 


"i 75' 


_ 


185 


190 


III 


—- — 

200 


206 


210 


,215 


__I 
220 225 


230 


18 20 ~ 






J25 


130 


Llil. 


140 


"145 


7Io 


1 5S 


w 


.111 


170 


175 


jlli 


785 


! ^ 

190 


"195 




m 




™ 


220 


— — » 

2251230 




0.21 




gLS 


TANl 

.1211 


w?p Ct. 


EAR; 
190 


___ 

195 






I <l'5 


™,™1.™^ 


..„.;„„ 


140 


1 45 


150 


1 55 


160 


111 


7 70 

III 


180 


J85 


"Too" 


205 


2 To 


215 


280 


225 

~n. ™ 


230 


iaTiTiio 




ImPl~'o37~ 


t| 


135 


M 


__, 


150 

__ 


_S5 


m 


Its 


.170 


180 


lis 


190 


__ 


200 


205 


2?0 


91 c 


___ 

220 


——■ 


230 








~M~~QA2. " 


""— ™» 


1 40 
™ 


145 


__ 




160 


m 


170 


Jz_. 


180 


lis 


foil 


J95 


200 


285 


__ 


215 


220 


1725 


230 


™ , 7 — - 


240 






0^4-3 ■ 0..47 


J40 


145 


1 50 


»_™„ „ 


m 


185* 
— ™,. 


170 


175 


180 


185 


190 


III! 




205 


"770 


215' 


220 


"888J 


730 




»™ — 

24(). 






_li§,.~,„112_. 


,14,5 


ill! 


III 


160 


jiii 


1 70 


111 


180 
___ 


lis 


HE. 


M 


200 




___ 


7177 


— — 




230 


235"' 


240 










1 00 
—8 




"185 


170 


775 


J80 


__ 




195 


200 


__, 


HI 


111 


Ho 


225 


230 


235 


240 






._l:.§iL2.,_9l§2 




160 
^. — 




__. 


175 


Tab 


185' 
__ 




__ 

195 


200 




210 


215 




OOK 


•^77 


— ™— 


240 






0.63 0,67 


1 80 : 


1 85 
— 


170 

___ 




J,M 


185 




M 


M 


205 


jio 


275 




2125 


230 


II 


240 








1 65 


m ™. nm ~™^ 


,.„.„.,.,™ hw ™ 


J80 


185 


190 


795 


200 


205 


Till 


ili. 




00 c: 


230 


™™.~™ 








™~~ Z ™,„ 


1 70 


...1Z1. 


_i__ 


185 


lil 


195 


200 


90K 


III 


215 


220 


225 


77777 




fit 








JL_i 


m 


1 85 


____ 


J* 


200 




HI 


215 


220 


225 




-— 


240" 






0.83 87 






0880 


1 95 


£881 


205^ 


_7o 


_ 


220 


225 


2777 


;ll 


M 






_0_88_2_i0lig 


185 


, : — 


III 


200 


205 


27o 


215 


220 


225 


~^r 


235". 


240 




Example: 


0,93 0,9"/ 


190 


195 


200 


205 


111 


215 


220 


— — 


935" 


____, 


240 




Valve Clearance (colon 


0.98 7.02 


795 


"200 


7Jf\f~ 


111 


215 


220 


225 


£81 


237 


240 




ft 91 ~ n 8A mm 




200 




III 


215 


220 


888 


230' 




24(7 





D«. ,».,i.-.,.I ,._i or 




205 


2"i*0 


215 


ill 


225 


230 


235: 


III 




nuuituey vaiut; i to 


, 1 , < 1 


210' 


I •. 


t80i 


.225 


230 




240 




Measured vaive clearance is 0.35 mm 


1 ' 1 


2 1 5 


22<i 


225 


230, 


__, 


240 




Replace pacJ 150 with pad 185 




22? 


228; 




^lizj 


240; 




Pad No. 175 = 1 „7fi mm 


1 ,28 1 .32 

_______ 


225'' 


230: 


235 


240; 




Pari Mn 1QR _ 1 OK n-, m 


____________ 


?30 ■ 




~™ — 
240 




ti w« * -■\*r» FUU — « ,W%/ Hilli 




til! 


2401 




mi way. liisiaii trie vaive paa wren me 


___„. . -—— — | 


840 


























r 


um 


oerl 


acir 


igcl 


own 













3-15 



ADJUSTING THE VALVE CLEARANCE/ 
SYNCHRONIZING THE CARBURETORS 



CHK |p§ 
ADJ Ht 



g. Measure the valve clearance again. 

h. If the valve clearance is still out of specifica- 
tion, repeat all of the valve clearance adjust- 
ment steps until the specified clearance is 

obtained. 



7. install: 
• all removed parts 

NOTE: ______ 



For installation, reverse the removal procedure 
Note the following points. 



8. install: 
•timing chain guide (exhaust side) 
•timing chain tensioner 
• pickup coil rotor cover 
•cylinder head cover 
•spark plugs 
•ignition coils 
Refer to "CAMSHAFTS" in chapter 4. 



SYNCHRONIZING THE CARBURETORS 

NOTE; _______^^ 

Prior to synchronizing the carburetors, the valve 
clearance and the engine idling speed should 
be properly adjusted and the ignition timing 
should be checked. 

1 . Stand the motorcycle on a level surface. 
NOTE: «— _______ _______ 

Place the motorcycle on a suitable stand. 

2. Remove): 
• rider seat 
•fuel tank 

Refer to "SEATS" and "FUEL. TANK". 



3-16 



SYNCHRONIZING THE CARBURETORS 






% 4fer?% 






r ult* 

: S2_ — J 



CHK i ft} 
ADJ ' M 



3, Remove 

• ho 



4, Install: 
•vacuum gauge attachments 
(into the bolt holes) 

• vacuum gauge (i) 

(onto the vacuum gauge attachments 

• engine tachometer" (2) 

(onto the iqnition coil of cylinder #1 ) 






Va.cyym gayge 

90890-03094, YU-08030-A 

¥acyym gauge attachment 

90890-03060 
Engine tachometer 

§07§3-800Q9 



5. Start the engine and let it warm up for several 
minutes. 



6. Measure: 

• engine idling speed 
Out of specification -+ Adjust, 
Refer to "ADJUSTINC IGINE ID- 

LING SPEED". 



C) 



Engine idling speed 
1,250 ~ 1,380 r/min 






7. Adjust: 

• carburetor synchronization 
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 
a. Synchronize carburetor #1 to carburetor #2 
by turning the synchronizing screw (1) in ei- 
ther direction until both gauges read the 
same. 



3-17 



SYNCHRONIZING THE CARBURETORS/ 
ADJUSTING THE ENGINE IDLING SPEED 






li"'@ " 



CHK 
"AD J 



<$ 



NOTE: - 



After each step, rev the engine two or three 
times, each time for less than a second, and 

check the synchronization again, 



b. Synchronize carburetor #4 to carburetor #3 

by turning the synchronizing screw (2) in ei- 
ther direction until both gauges read the 
same. 

c. Synchronize carburetor #2 to carburetor #3 
by turning the synchronizing screw (3) in ei- 
ther direction until both gauges read the 
same. 






NOTE: 



Yacyum pressure at engine 
idling speed 

24.0 kPa (0.24 kg/cm 2 , 3,41 psi) 



The difference in vacuum pressure between 
two carburetors should not exceed 1 .33 kPa (10 
mm Hg). 



8. Measure: 
•engine idling speed 

Out of specification ► Adjust. 

9. Stop the engine and remove the measuring 
equipment. 

10. Adjust: 

•throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY". 




Throttle cable free play 
(at the flange of the throttle grip) 
6 8 mm (0.24 0,31 in) 



ADJUSTING THE ENGINE IDLING SPEED 

NOTE: ^^^^^^_^ 

Prior to adjusting the engine idling speed, the 
carburetor synchronization should be adjusted 
properly, the air filter element should be clean, 
and the engine should have adequate com- 
pression. 



1 . Start the engine and let it warm up for several 
minutes. 



3-18 



ADJUSTING THE ENGINE IDLING SPEED 




CHK ! lol 



2. Remove: 
•air filter case 
•quick fasteners (i) 
• band (2) 

Refer to "AIR FILTER CASE AND IGNITION 

COILS", 



3. Install: 
• engine tachometer 

(onto the ignition coil of cylinder #L 



f- 



Engine tachometer 
90793-80009 



4, Install: 

•air filter case 

Refer to "AIR FILTER CASE AND IGNITION 
COILS". 

5. Measure: 
•engine idling speed 

Out of specification -+ Adjust, 



C\ 



Engine idling speed ' 
1,250 ~ 1,350 r/min 



6. Adjust: 
•engine idling speed 




a. Turn the throttle stop screw (2) in direction (D 
or (6) until the specified engine idling speed is 

obtained. 



Direction fad En 3 ine icl,in 3 s P eed is 
""' decreased. 



Direction ( 



Engine idling speed is 
increased. 



3-19 



ADJUSTING THE ENGINE IDLING SPEED/ 
ADJUSTING THE THROTTLE CABLE FREE PLAY 



CHK 
AD J 



<a 



7. Adjust: 

• throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY", 




Throttle cable free play 
(at the flange of the throttle grip) 
6 - 8 mm (0.24 0.31 in) 



ADJUSTING THE THROTTLE CABLE FREE 
PLAY 



NOTE: __^____^^ 

Prior to adjusting the throttle cable free play, the 
engine idling speed and carburetor synchro- 
nization should be adjusted properly. 




Measure; 

•throttle cable free play (a) 
Out of specification -+ Adjust, 



m 



i\ 



Throttle cable free play 
(at the flange of the throttle grip) 
6 ■- 8 mm (0.24 - 0,31 in) 



2, Remove: 

• rider seat 
•fuel tank 

Refer to "SEATS" and "FUEL TANK", 
•air filter case 

• heat protector plate 

Refer to "AIR FILTER CASE AND IGNITION 
COILS", 



3-20 



ADJUSTING THE THROTTLE CABLE FREE PLAY 



CHK 
ADJ 



M 






Je 
% \ \ 



m > • \ * ( f \ V ' \ 



•^ - 



^^'^(d)^ l 



a V* 5 : 






3. Adjust: 
•throttle cable free play 

W W If ▼ W W ▼ ▼ "W W W °W W W W W W T?T?f TT??f f f 

NOTE; ____^^^ 

When the throttle is opened, the accelerator 

cable (1) is pulled. 

Carburetor side 

a. Loosen the locknut (2) on the decelerator 

cable. 

b. Turn the adjusting nut (3) in direction (a) or® 
to take up any slack on the decelerator cable. 

c. Loosen the locknut (4) on the accelerator 
cable. 

d. Turn the adjusting nut© in directic 

until the specified throttle cable freej play is 
obtained. 



Direction a Throttle cab,e free P ,a y 
v - ' in increased. 



Direction ( 



Throttle cable free play 
is decreased. 



e. Tighten the locknuts. 

NOTE; ________ 



If the specified throttle cable free play cannot be 
obtained on the carburetor side of the cable, 
use the adjusting nut on the handlebar side. 



Handlebar side 

a. Loosen the locknut ©. 

b. Turn the adjusting nut (7) in direction© or® 
until the specified throttle cable free play is 
obtained. 



Direction ( 



Throttle cable free play- 
is increased. 



Direction (ft Th ? tt,e CaWe free p,ay 



is decreased. 



_J 



d. Tighten the locknut. 



A WARNING 



After adjusting the throttle cable free play, 
start the engine and turn the handlebars to 
the right and to the left to ensure that this 
does not cause the engine idling speed to 
change. 



0~.c I 



CHECKING THE SPARK PLUGS 



ADJ W 



CHECKING THE SPARK PLUGS 

The following procedure applies to all of the 
spark plugs. 
1 Remove: 

• rider seat 
•fuel tank 

Refer to "SEATS" and "FUEL TANK". 
•airfilterca.se 

• heat protector plate 

Refer to "AIR FILTER CASE: AND IGNITION 
COILS". 

2. Disconnect: 

• Ignition coils 

3. Remove: 
•spark plug 

NOTE; _____^^ 

a. Remove the coupler, 

b. Turn the coil counterclockwise. (5 to 6 turns 

would be adequate.) 

c. Pull out the coil upward. 

Never pry the coupler with a screw driver. 

d. Press the coil in the plug hole by hand as fa- 
ras it will go. 

e. Turn the coil clockwise and screw it in, 5 to 6 
turns would be adequate. 

f. Reins tall the coupler. 

Do not strike on the coil with a hammer or the 
like. 

CAUTION; 



Before removing the spark plugs, blow 
away any dirt accumulated in the spark plug 
wells with compressed air to prewent it from 
falling into the cylinders. 

4, Check: 
•spark plug type 
Incorrect - ► Change. 



r 



Spark plugs 

type (manyfactyrer) 
CR10EK{NGK) 
CR3EK (NGK) (California) 



3-22 



CHECKING THE SPARK PLUGS/ 
CHECKING THE IGNITION TIMING 






w 



_»j 'm-m «.. 




5. Check: 

• electrodes (j) 

Damage/ wear ► Replace the spark plug. 

• insulator (2) 

Abnormal color ► Replace? the spark plug. 

Normal color is medium-to-light tan, 

6. Clean: 

• spark plug 

(with a spark plug cleaner or wire brush) 

7. Measure: 
•spark plug gap •* 

(with a wire; gauge) 

Out of specification - ► Regap. 



^ 



Spark plyg gap 

0,6 0,7 mm (0.02 ~ 0.03 in) 



8. install: 




•spark plug 


;Hn»f«| M-l fMb»I 


NOTE - - - — 




Before installing the spark plug, 
plug and gasket surface. 


clean the spark 



CHECKING THE IGNITION TIMING 
NOTE; ______^^ 

Prior to checking the ignition timing, check the 
wiring connections of the entire ignition system. 
Make sure that all connections are tight and free 
of corrosion. 





\\ \ 1 lf^ i __ 


1 1 1 






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1 V/ 


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5 :• . • 




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t. Remove; 

• bottom cowling 

Refer to "COWLINGS", 

• rider seat 

• fuel tank 

Refer to "SEATS" and "FUEL TANK", 

• air filter case 

Refer to "AIR FILTER CASE AND IGNITION 
COILS". 

• timing mark aco 



3-23 



CHECKING THE IGNITION TIMING/ 
MEASURING THE COMPRESSION PRESSURE 



fs 



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CHK 401 
ADJ Vi 



Install: 

"timing light (1) 
•engine tachometer 

(onto the ignition coil of cylinder #1) 



r 



Timing light 

90890-03 1 41 , Y U-33277- A 
Engine tachometer 

90793-80009 



Check: 
> ignition timing 



a. Start the engine, warm it up for several min- 
utes, and then let it run at the specified en- 
gine idling speed. 



C\ 



Engine idling speed 
1,250 ~ 1,350 r/min 



b. Check that the mark® is within the required 
firing range (B) on the pickup coil rotor. 

Incorrect firing range - *■ Check the ignition 

system. 

NOTE: ^____^^ 

The ignition timing is not adjustable. 



MEASURING THE COMPRESSION PRES- 
SURE 

The following procedure applies to all of the cyl- 
inders. 

NOTE: —————— ——————— 

Insufficient compression pressure will result in a 
loss of performance. 

1. Measure: 
•valve clearance 

Out of specification > Adjust. 

Refer to "ADJUSTING THE VALVE CLEAR- 
ANCE". 

2. Start the engine, warm it up for several min- 
utes, and then stop it. 

3. Remove: 

• rider seat 

• fuel tank 

Refer to "SEATS" and "FUEL TANK". 

• air filter case 

• heat protector plate 

• ignition coils 

Refer to "AiR FILTER CASE AND IGNITION 
COILS". 



3-24 



MEASURING THE COMPRESSION PRESSURE 



f. Remove: 

•spark plug 

CAUTION: 



CHK 
ADJ 



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W 


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if I f 


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12 




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\ \ i \ 




// 



Before remowing the spark plygs, use com- 
pressed air to blow away any dirt accumu- 
lated in the spark plyg wells to prevent it 
from falling into the cylinders. 



5. Install: 
•compression qauq© (1.i 






Compression gayge 

90890-03081, YU-33223 

Adapter 

90890-04138 



6, Measure: 

• compression pressure 

Out of specification ► 

(d). 



Refer to steps (c) and 





Compression pressure (at sea 


level) 




Minimym 




1300 kPa (13,0 kg/cm 2 , 




184.90 psl) 




Standard 




1550 kPa (15.5 kg/cm 2 , 




224.75 psi) 




Maximum 




1800 kPa(l 6.0 kg/cm 2 , 




227.57 psi) J 



TffTTTfTTTfTTTTTTTfTTTfffT ▼ ▼ W 

a. Set the main switch to "ON". 

b. With the throttle wide open, crank the engine 

until the reading on the compression gauge 
stabilizes. 



A WARNING 



To pre¥ent sparking, groynd all spark plyg 
leads before cranking the engine. 



NOTE: _____^_^^ 

The difference in compression pressure be- 
tween cylinders should not exceed 100 kPa (1 
kg /cm 2 , 14.22 psi). 



8-25 



MEASURING THE COMPRESSION PRESSURE/ 
CHECKING THE ENGINE OIL LEVEL 



CHK 
ADJ" 



<& 



d. 



If the compression pressure is above the 
maximum specification, check the cylinder 

head, valve surfaces, and piston crown for 

carbon deposits. 

Carbon deposits -+ Eliminate. 

If the compression pressure is below the 

minimum specification, squirt a few drops of 

oil into the cylinder and measure again. 



Refer to the following table. 



Compression pressure 
(with oil applied into the cylinder) 


Reading 


Diagnosis 


Higher than 
without oil 


Piston wear or 
damage -+ Repair, 


Same as withoyt 
oil 


Piston ring(-s), 
valve(-s), cylinder 
head gasket or 
piston possibly 

defective + 

Repair, 



7. install: 
• spark plug 



ill3~iii«ki79.4 fMb) 



EB30307Q 



CHECKING THE ENGINE OIL LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE; _______^^ 

• Place the motorcycle on a suitable stand. 

• Make sure) that the motorcycle is upright. 

2. Start the engine, let it idle for several min- 
utes, and then stop it. 




3. Check: 
•engine oil level 

The engine oil level should be between the 
minimum level mark (§) and maximum level 
mark®. 

Below the minimum level mark -> Add the 
recommended engine oil to the proper level. 



3^26 



CHECKING THE ENGINE OIL lEWEt/ 
CHANGING THE ENGINE OIL 



0' 10" 30* 50" 70' 90' 110' 130"F 



""20 -10' 0' 10' 20 30" 40" 5G"C 



CHK 
ADJ 



<a 



•Y> 


Recommended oil: 

At- 10 C(10 F) or higher [A]: 

Yamaiube4(10W-30) 
orSAE 

10W-30 type SE motor oil 
At5*C(40 F) or higher [i: 

Yamalube 4 (20W-40) 
orSAE 

20W-40 type SE motor oil 





CAPTION: 



•Engine oil also lubricates the clytch and 
the wrong oil types or additiwes coylci 
cayse clytch slippage. Therefore, do not 
add any chemical additives, 

• Do not allow foreign materials to enter the 
crankcase. 



NOTE: _______^^ 

API Service "SE", "SF" and "SG" type or equiva- 
lent (e. g.. "SF-SE", "SF-SE-CC,' "SF-SE-SD") 

4, Start the engine, warm it up for several min- 
utes, and then turn it off. 

5. Check: 
•engine oil level 

NOTE: ______^^ 

Before checking the engine oil level, wait a few 
minutes until the oil has settled. 



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1 



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CHANGING THE ENGINE OIL 

1. Remove: 
•bottom cowling 

Refer to "COWLINGS". 

2. Start the engine, warm it up for several min- 
utes, and then turn it off. 

3. Place a container under the engine oil drain 
bolt. 

4. Remove: 
•engine oil filler c 
•engine oil drain bolt (2) 

(along with the washer) 

5. Drain: 

• engine oil 
(completely from the crankcase) 



3-27 



CHANGING THE ENGINE OIL 




CHK 
ADJ" 



<& 



6. If the oil filter cartridge is also to be replaced, 
perform the following procedure. 



a, Remove the oil filter cartridge 

filter wrench®. 



with an oil 



/ 



/2, 



Oil filter wrench 

90890-01426, YU-38411 



b. Lubricate the O-rirv the new oil filter 

cartridge with a thin coat of engine oil. 

CAUTION: 



Make syre theat the O-ring (3) is positioned 
correctly in the groove of the oil filter car- 
tridge. 

c. Tighten the new oil filter cartridge to specifi- 
cation with an oil filter wrench. 



_ 



w 



Oil filter cartridge 

17Nm(1.7m*kg, 12fMb) 



7, Check: 

•engine oil drain bolt washer 
Damage ► Replace. 

8, Install: 

•engine oil drain bolt 



9. Fill: 
• crankcase 

(with the specified amount of the recom- 
mended engine oil) 



•tt 



Quantity 

Total amount 

3,5 L (3,7 US qt) 

Without oil filter cartridge re- 
placement 

2,5 L (2,64 US qt) 
With oil filter cartridge replace- 
ment 

2.7 L (2,85 US qt) 



10. Install: 

• engine oil filler cap 

1 1 . Start the engine, warm it up for several min- 
utes, and then turn it off. 

12. Check: 
•engine 

(for engine oil leaks) 



3-28 



CHANGING THE ENGINE OIL/ 
MEASURING THE ENGINE OIL PRESSURE 



CHK 
AD J" 



<a 



13. Check: 

• engine oil level 

Refer to "CHECKING THE ENGINE OIL 
LEVEL" 

14. Install: 

• bottom cowling 

Refer to "COWLINGS". 






ten 



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MEASURING THE ENGINE OIL PRESSURE 

1. Check: 

• engine oil level 

Below the minimum level mark ► Add the 

recommended engine oil to the proper level. 

2. Start the engine, warm it up for several min- 
utes, and then turn it off. 

CAUTION: 



When the engine is cold, the engine oil will 
have a higher viscosity, causing the engine 
oil pressure to increase. Therefore, be sure 
to measure the engine oil pressure after 
warming up the engine, 

3. Remove: 
•oil gallery bolt© 



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The engine, muffler and engine oil are ex- 
tremely hot, 

4. Install; 
•oil pressure gauge© 
•adapter (2) 



\>/, Oil pressure gauge 






90890-03153 
Adapter 

90890-03139 



5. Measure: 

•engine oil pressure 
(at the following conditions) 



M 

^>-\ 



Engine oil pressure 

240 kpa (2,4 kg/cm 2 , 34,1 psi) 
Engine speed 

Approx. 8000 r/min 
Engine oil temperature 

98 C (205'T) 



3-29 



MEASURING THE ENGINE OIL PRESSURE 



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ADJ 



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NOTE: _______^^ 

Regarding the oil pressure as its own data may 
fluctuate depending on the oil temperature and 
viscosity, the oil pressure may fluctuate when 
measuring. The following data should be used 
only as a reference when measuring the engine 
oil pressure. 

Out of specification ► Adjust, 



Engine oil pressure 


Possible cayse 


Below specification 


Faulty oil pump 
Clogged oil filter 
Leaking oil passapage 
Broken or damaged 
oil seal 


Above specification 


Leaking oil passage 

Faulty oil filter 

OH viscosity too high 



8. Tighten the oil gall ery bolt ___ __ _ 

" rXT20"Nm"(2.0' ro») i 



ADJUSTING THE CLUTCH CABLE FREE 
PLAY 

1. Measure: 
•clutch cable free pi; 
Out of specification -+ Adjust, 



/a^ Clutch cable free play (at the end 
^xL 1 of the clutch lever) 



_±2sJ 



10 - 15 mm (0.39 ~ 0,59 in) 



!. Adjust: 
•clutch cable free play 



Handlebar side 

a. Turn the adjusting bolt© in directit 

until the specified clutch cable free play is ob- 
tained. 



Direction 
Direction 



=-., I Clutch cable free play is im- 
-'I creased. 

u-,j Clutch cable trt»t» play is cfe- 
-O creased. 



NOTE: ________ _____^_ 

If the specified clutch cable free play cannot be 
obtained on the handlebar side of the cable, use) 
the adjusting nut on the engine side. 



Engine side 

a. Loosen the lockout Q 

b. Turn the adjusting nu 
until the specified" clui 

tained. 



i direction© or(d) 

ble free play is ob- 



jection (c) Clutch cable free play is in- 

"" creased. 



niroMrttinn OT Clutch cable free play is de- 
uirecuon [a, creased# 



c. Tighten the lockout, 

AAAAJkJkAAJkAjtkMM,AdkM,AAJkAAA.AJkAAAAA 



3-30 



CLEANING THE AIR FILTER ELEMENT 



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CHK 
ADJ 



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CLEANING THE AIR FILTER ELEMENT 
1. Remove: 

•fuel tank 

Refer to "FUEL TANK", 
•air filter case cover (j) 
•air filter element 



2. Clean: 

•air filter element 
Use solvent to clean the air filter element. Af- 
ter cleaning the air filter element, remove the 
solvent from the air filter element, 

3. Apply the engine oil to the entire surface of 
the filter and remove the excess oil. The air 
filter should be wet but not dripping, 

4. Check; 

•air filter element 
Damage -+ Replace. 

5. Install: 

•air filter element 
• air filter case cover 

CAUTION: 



Never operate the engine withoyt the air fil- 
ter element installed, Unfiitered air will 
cause rapid wear of engine parts and may 
damage the engine. Operating the engine 
without the air filter element will also affect 
the carbyretor toning, leading to poor en- 
gine performance and possible overheat- 
ing. 



NOTE; _______^^ 

When installing the air filter element into the air 
filter case cover, make sure that their sealing 
surfaces are aligned to prevent any air leaks. 

6. Install: 
•fuel tank 
Refer to "FUEL TANK". 



3-31 



CHECKING THE CARBURETOR JOINTS/ 
CHECKING THE FUEL HOSES AND FUEL FILTER/ 





CHECKING THE CARBURETOR JOINTS 
The following procedure applies to all of the car- 
buretor joints and intake manifolds. 

1. Remove: 

• carburetor assembly 
Refer to "CARBURETORS" in chapter 6. 

2. Check; 

•carburetor joint CD 

Cracks/darn. )!ace. 

Refer to "CARBURETORS" in chapter 8. 

3. Install: 
•carburetor assembly 

Refer to "CARBURETORS" in chapter 6. 



EB303I81 

CHECKING THE FUEL HOSES AND FUEL 

FILTER 

The following procedure applies to all of the fuel 

hoses, 
1. Remove: 
•fuel tank 
Refer to "FUEL TANK", 




■Z^f 




2, Check: 
• fuel hose (J) 

Cracks/damage -*■ Replace, 
•fuel filter (2) 

Contaminants/damage ► Replace. 

NOTE: ———————— _____ 



• Drain and flush the fuel tank if abrasive darn- 
age to any components of the fuel line is evi- 
dent. 

• The arrow mark on the fuel filter must point to- 
wards the fuel pump as shown. 



3, Install: 
•fuel tank 
Refer to "FUEL TANK". 



3-32 



CHECKING THE CRANKCASE BREATHER HOSE/ 
CLEANING THE AIR INTAKE SYSTEM 



W 



i -— nf =^ 



l\ + , r , "Iff --< -V I 1 




CHECKING THE CRANKCASE BREATHER 
HOSE 

1 . Remove: 

• fuel tank 

Refer to "FUEL TANK", 

2. Check: 

• crankcase breather hose (1) 
Cranks/damage ► Replace, 

Loose connection >■ Connect properly, 

CAUTION: 



Make sure that the crankcase breather hose 
is routed correctly. 



3. install: 
•fuel tank 
Refer to "FUEL TANK - *. 




CLEANING THE AIR INTAKE SYSTEM 

The following procedure applies to both air in- 
take system. 



1 



e. 



5. 



Remove: 

• side cowling inner covers 

• side cowlings 

• front cowling inner covers 

• front cowling 
•fuel tank 

Loosen: 

• clamps 

(on the inside of the front cowling) 
Remove: 

•air intake system air ducts (!) 
Clean: 

• air intake system air ducts 

Thoroughly flush out the air intake system air 
ducts with clean water. 
Hold the air intake system air ducts upside 
down to allow the water to drain out. 
Repeat the flushing steps until the excess 
water is clear and free of debris. 
Place the air intake system air ducts in an up- 
right position to allow any remaining water to 
drain out of the lower drain tube. 
Keep the air intake system air ducts upright 
to allow it to dry sufficiently. 
install: 

• air intake system air ducts 

• fuel tank 

• front cowling 

• front cowling inner covers 

• side cowlings 

•side cowlings inner covers 



3-33 



CLEANING THE AIR INTAKE SYSTEM/ 
CHECKING THE EXHAUST SYSTEM 



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CHK ink 

ADJ M 



2, Check; 
• crankcase breather hose (1) 
Cracks/damage -+ Replace, 
Loose connection -f Connect properly, 

CAUTION; 



Make sure that the crankcase breather hose 
is routed correctly*. 



3. install; 
• fuel tank 
Refer to "FUEL TANK" 




CHECKING THE EXHAUST SYSTEM 
The following procedure applies to al! of the ex- 
haust pipes and gaskets. 

1 . Remove; 

• radiator assembly 

Refer to "RADIATOR" in chapter 5, 

2. Check; 

• exhaust pipe (T) 

• muffler (2) 
Cracks/damage -+ Replace. 

• gasket (3) 

Exhaust gas; leaks ► Replace. 

3. Measure: 
•tightening torque 



\/7 


Exhaust pipe nut (4) 


€^Cx 


20 Nm (2.0 m*kg, 14 ft»lb) 


-~~~- i Muffler clamp bolt (5) 


20 Nm (2.0 m-kg. 14 1Mb) 


Exhaust pipe bolt (8) 


20 Nm (2.0 m*kg. 14 fflb) 


Muffler bolt 17) 


38 Nm (3.8 m«kg, 27 fMb) 



4. Install: 
• radiator assembly 
Refer to "RADIATOR" in chapter 5 



3-34 



CHECKING THE COOLANT LEVEL/ 
CHECKING THE COOLING SYSTEM 



CHK 
ADJ 



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CHECKING THE COOLANT LEVEL 

1 , Stand the motorcycle on a level surface, 
NOTE; ________ ___________ 

• Pla torcycle on a suitable stand, 

• Make sure that the motorcycle is upright. 

2, Check: 

• coolant level 

The coolant level should be between the 
maximum level mark (a) and minimum level 
marks (6). 

Below the minimum level mark + Add the 

recommended coolant to the proper level. 

CAUTION; ___^^ 

• Adding water instead of coolant lowers the 
antifreeze content of the coolant if water is 
used instead of coolant, check and correct 
the antifreeze concentration of the coolant, 

• Use only distilled water. Soft water may be 
ysed if distilled water is not available, 

3. Start the engine, warm it up for several min- 
utes, and then turn it off. 

4. Check: 

• coolant level 

NOTE: ________ ________ 

Before checking the coolant level, wait a few 
minutes until it settles. 



CHECKING THE COOLING SYSTEM 

1. Remove: 
•bottom cowling 
•side cowlings 

Refer to "COWLINGS", 

2. Check: 

• radiator (t) 

• radiator inlet hose (2) 

• radiator outlet hose (3) 

• oil cooler (4) 

•oil cooler inlet hose (5) 

• oil cooler outlet hose (!) 

• water pump outlet hose (7) 
Cracks/damage -+ Replace. 

Refer to "COOLING SYSTEM" in chapter 5. 

3. Install: 
•side cowlings 

• bottom cowling 
Refer to "Cowlings", 



3-35 



CHANGING THE COOLANT 



CHK 
ADJ 



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CHANGING THE COOLANT 

1, Remove: 
•bottom cowling 
•left side cowling 

Refer to "COWLINGS". 

•reservoir hose clamps (1) 

2, Remove: 

•coolant reservoir bolts (2) 
•coolant reservoir cap (3) 

When draining the coolant from the; coolant res- 
ervoir; be sure to tilt the reservoir so that coolant 
cannot flow through the coolant reservoir 
breather hose (J). 

3, Drain: 

• coolant 
(from the coolant reservoir) 

4, Install: 

•coolant reservoir belts 
•reservoir cover 




5. Remove: 
• radiator cap Q) 



A WARNING 



A hot radiator is ynder pressure. Therefore, 
do not remove the radiator cap when the en- 
gine is hot. Scalding hot fluid and steam 
may be blown out, which coylcl cause seri- 
ous injury. When the engine has cooled, 
open the radiator cap as follows: 
Place a thick rag or a towel over the radiator 
cap and slowly turn the radiator cap coun- 
terclockwise toward the detent to allow any 
residyal pressure to escape. When the his- 
sing sound has stopped, turn the radiator 
cap counterclockwise while pressing down 
on it and then remove it. 



■38 



CHANGING THE COOLANT 



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ADJ !M 



6. Remove: 

• coolant drain bolt CD 

(along with the copper washer) 

7. Drain: 

• coolant 

8. Check: 
•coper washer© 
•coolant drain bolt (2) 

Damage > Replace 



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9. Install: 

•coolant drain b 



ii (0.7 m*kg, 5,1 fWb) 




10. Fill: 

•cooling system 
(with the specified amount 
mended coolant) 



of tti© rscom- 




RecommendecJ antifreeze 

High-quality ethylene glycol 
antifreeze containing corrosion 
inhibitors for aiyminym engines 

Mixing ratio 

1:1 (antifreeze: water) 

Quantity 

Total amount 

2.15 L (2,27 US qt) 
Coolant reservoir capacity 
0.44 L (0,47 US qt) 



Handling notes for coolant 

Coolant is potentially harmful and should be 
handled with special care. 



Ak. 1A/A DMIMP > 



• if coolant splashes in your eyes, thorough- 
ly wash them with water and consult a doc- 
tor, 

• If coolant splashes on your clothes, quick- 
ly wash it away with water and then with 
soap and water, 

•If coolant is swallowed, incJyce vomiting 
and get immediate medical attention. 



3-37 



CHANGING THE COOLANT 



CHK 
ADJ 


<a 



CAUTION: 



• Adding water instead of coolant lowers the 
antifreeze content of the coolant. If water is 
used instead of coolant, check, and if nec- 
essary, correct the antifreeze concentra- 
tion of the coolant. 

• Use only distilled water. However, soft wa- 
ter may be used if distilled water is not 
available. 

• If coolant comes into contact with painted 
surfaces, immediately wash them with wa- 
ter. 

• Do not mix different types of antifreeze. 

11. Install: 
• radiator cap 




12. Fill: 
•coolant reservoir 

(with the recommended coolant to the maxi- 
mum level mark®) 

13. Install: 

•coolant reservoir cap 

1 4. Start the engine, warm it up for several min- 
utes, and then turn it off. 



15. Check: 

• coolant level 
Refer to "CHECKING THE COOLANT LEV- 
EL". 

NOTE: 

Before checking the coolant level, wait a few 
minutes until the coolant has settled. 

16. Install: 

•left side cowling 
•bottom cowling 
Refer to "COWLINGS". 



3-38 



ADJUSTING THE FRONT BRAKE/ 
ADJUSTING THE REAR BRAKE 



CHK 
ADJ 


<a 




CHASSIS 

ADJUSTING THE FRONT BRAKE 

1. Adjust: 
•brake lever position 
(distance (a) from the throttle grip to the 
brake lever) 

a. While pushing the brake lever forward, turn 
the adjusting dial CD until the brake lever is in 
the desired position. 

NOTE: 

Be sure to align the setting on the adjusting dial 
with the arrow mark (2) on the brake lever hold- 
er. 




Position #1 



Position #5 



Distance (a) is the largest. 



Distance (a) is the smallest. 



A WARNING 



After adjusting the brake lever position, 
make sure that the pin on the brake lever 
holder is firmly inserted in the hole in the ad- 
justing dial. 



ADJUSTING THE REAR BRAKE 

1. Measure: 
• brake pedal position 
(distance (§) from the top of the brake pedal 
to the bottom of the rider footrest bracket bolt 
center) 
Out of specification — ► Adjust. 




Brake pedal position (from the 
top of the brake pedal to the 
bottom of the rider footrest 
bracket bolt center) 

4.3 ~ 9.3 mm (0.17 ~ 0.37 in) 



11mm (0.43 in) 



3-39 



ADJUSTING THE REAR BRAKE 




CHK 
ADJ 


<& 



2. Adjust: 
• brake pedal position 



a. Loosen the locknut©. 

b. Turn the adjusting bolt© in direction @ or® 
until the specified brake pedal position is ob- 
tained. 



Direction (a) 


Brake pedal is raised. 


Direction (b) 


Brake pedal is lowered. 



A WARNING 



After adjusting the brake pedal position, 
check that the end of the adjusting bolt © is 
visible through the hole (d). 

c. Tighten the locknut© to specification. 



X 



\ 



Locknut 

16Nm(1.6nvkg, 12ft«lb) 



A WARNING 



A soft or spongy feeling in the brake pedal 
can indicate the presence of air in the brake 
system. Before the vehicle is operated, the 
air must be removed by bleeding the brake 
system. Air in the brake system will consid- 
erably reduce braking performance and 
could result in loss of control and possibly 
an accident. 

Therefore, check and, if necessary, bleed 
the brake system. 

CAUTION: 



After adjusting the brake pedal position, 
make sure that there is no brake drag. 



3. Adjust: 
• rear brake light switch 
Refer to "ADJUSTING THE REAR BRAKE 
LIGHT SWITCH". 



3-40 



CHECKING THE BRAKE FLUID LEVEL 



CHK 
ADJ 


<a 



CHECKING THE BRAKE FLUID LEVEL 

1 . Stand the motorcycle on a level surface. 

NOTE: . 

• Place the motorcycle on a suitable stand. 
•Make sure that the motorcycle is upright. 




2. Check: 
• brake fluid level 
Below the minimum level mark® -+ Add the 
recommended brake fluid to the proper level. 



>X} 



Recommended brake fluid 
DOT 4 



[A] Front brake 
\B\ Rear brake 



A WARNING 



• Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

•When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 



CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 



NOTE: 

In order to ensure a correct reading of the brake 
fluid level, make sure that the top of the brake 
fluid reservoir is horizontal. 



3-41 



CHECKING THE BRAKE PADS/ 
ADJUSTING THE REAR BRAKE LIGHT SWITCH 



1ST 



<§> 



c 



^\_ 



zr 



2 



B] 


3) 


1 u 


1 


i ' 


. . . — j— — , 







CHK 
ADJ 


<a 



CHECKING THE BRAKE PADS 

The following procedure applies to all of the 
brake pads. 

1 . Operate the brake. 

2. Check: 

•front brake pad 
• rear brake pad 

Brake pad wear limit (a) 

Wear limit reached — ► Replace the brake 

pads as a set. 

Refer to "FRONT AND REAR BRAKES" in 

chapter 7. 




Brake pad wear limit 
(a) 0.5 mm (0.02 in) 
© 0.8 mm (0.03 in) 



[A] Front brake 
[Bj Rear brake 




ADJUSTING THE REAR BRAKE LIGHT 
SWITCH 

NOTE: 

•The rear brake light switch is operated by 

movement of the brake pedal. 
• The rear brake light switch is properly adjusted 

when the brake light comes on just before the 

braking effect starts. 

1. Check: 

• rear brake light operation timing 
Incorrect -► Adjust. 

2. Adjust: 

•rear brake light operation timing 

a. Hold the main body © of the rear brake light 
switch so that it does not rotate and turn the 
adjusting nut (2) in direction (a) or® until the 
rear brake light comes on at the proper time. 



Direction (a) 


Brake light comes on 
sooner. 


Direction (b) 


Brake light comes on 
later. 



3-42 



CHECKING THE BRAKE HOSES/ 
BLEEDING THE HYDRAULIC BRAKE SYSTEM 



CHK 
ADJ 


<a 




CHECKING THE BRAKE HOSES 

The following procedure applies to all of the 
brake hoses and brake hose clamps. 

1. Check: 
•brake hose© 

Cracks/damage/wear ->• Replace. 

2. Check: 

•brake hose clamp 
Loose -y Tighten the clamp bolt. 

3. Hold the motorcycle upright and apply the 
brake several times. 

4. Check: 

• brake hose 
Brake fluid leakage -+ Replace the damaged 
hose. 

Refer to "FRONT AND REAR BRAKES" in 
chapter 7. 



BLEEDING THE HYDRAULIC BRAKE SYS- 
TEM 



A WARNING 



Bleed the hydraulic brake system whenev- 
er: 
•the brake system was disassembled, 

• a brake hose was loosened, disconnected 
or replaced, 

•the brake fluid level is very low, 

• brake operation is faulty. 



NOTE: 

• Be careful not to spill any brake fluid or allow 
the brake fluid reservoir to overflow. 

•When bleeding the hydraulic brake system, 
make sure that there is always enough brake 
fluid before applying the brake. Ignoring this 
precaution could allow air to enter the hydrau- 
lic brake system, considerably lengthening the 
bleeding procedure. 

• If bleeding is difficult, it may be necessary to let 
the brake fluid settle for a few hours. Repeat 
the bleeding procedure when the tiny bubbles 
in the hose have disappeared. 



3-43 



BLEEDING THE HYDRAULIC BRAKE SYSTEM 



5. Bleed: 
• hydraulic brake system 



CHK 
ADJ 


<& 




a. Fill the brake fluid reservoir to the proper lev- 
el with the recommended brake fluid. 

b. Install the brake fluid reservoir diaphragm. 

c. Connect a clear plastic hose © tightly to the 
bleed screw (2). 

[A] Front brake 

[B] Rear brake 

d. Place the other end of the hose into a con- 
tainer. 

e. Slowly apply the brake several times. 

f. Fully squeeze the brake lever or fully de- 
press the brake pedal and hold it in position. 

g. Loosen the bleed screw. 



NOTE: 

Loosening the bleed screw will release the 
pressure and cause the brake lever to contact 
the throttle grip or the brake pedal to fully ex- 
tend. 

h. Tighten the bleed screw and then release the 

brake lever or brake pedal. 
i. Repeat steps (e) to (h) until all of the air 

bubbles have disappeared from the brake 

fluid in the plastic hose. 
j. Tighten the bleed screw to specification. 



V 



Bleed screw 

6 Nm (0.6 m«kg, 4.3 fl-lb) 



k. Fill the brake fluid reservoir to the proper lev- 
el with the recommended brake fluid. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL". 



A WARNING 



After bleeding the hydraulic brake system, 
check the brake operation. 



3-44 



ADJUSTING THE SHIFT PEDAL/ 
ADJUSTING THE DRIVE CHAIN SLACK 



CHK 
ADJ 


<a 




EB304081 

ADJUSTING THE SHIFT PEDAL 



NOTE: 

The shift pedal position is determined by the 
shift rod length. 

1. Measure: 
• incorrect -► Adjust. 




The top of sift pedal should be 
aligned with the lower part of the 
bracket, (from the horizontal view) 



2. Adjust: 
•installed shift rod length 



a. Loosen both locknuts©. 

b. Turn the shift rod (2) in direction (5) or © to 
obtain the correct shift pedal position. 



Direction © 


Installed shift rod length 
increases. 


Direction © 


Installed shift rod length 
decreases. 



c. Tighten both locknuts. 

d. Make sure that the installed shift rod length is 
within specification. 



ADJUSTING THE DRIVE CHAIN SLACK 

NOTE: 

The drive chain slack must be checked at the 
tightest point on the chain. 



CAUTION: 



A drive chain that is too tight will overload 
the engine and other vital parts, and one that 
is too loose can skip and damage the swin- 
garm or cause an accident. Therefore, keep 
the drive chain slack within the specified 
limits. 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



3-45 



NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



ADJUSTING THE DRIVE CHAIN SLACK 




CHK 
ADJ 


<a 



2. Rotate the rear wheel several times and 
check the drive chain to locate its tightest 
point. 

3. Measure: 

•drive chain slack® 
Out of specification -► Adjust. 




Drive chain slack 

40 ~ 50 mm (1.57 ~ 1.97 in) 



4. Adjust: 
•drive chain slack 



a. Loosen the wheel axle nut©. 

b. Loosen both locknutsd). 

c. Turn both adjusting bolts® in direction® or 
© until the specified drive chain slack is ob- 
tained. 



Direction @ 


Drive chain slack is 
reduced. 


Direction © 


Drive chain slack is 
increased. 



NOTE: 

To maintain the proper wheel alignment, adjust 
both sides evenly. 

d. Tighten both locknuts to specification. 



X 



'\ 



Locknut 

16Nm(1.6m»kg, 12 ft-lb) 



e. Tighten the wheel axle nut to specification. 



V 



Wheel axle nut 

150 Nm (15.0 m-kg, 108 fHb) 



3-46 



LUBRICATING THE DRIVE CHAIN/ 
CHECKING AND ADJUSTING THE STEERING HEAD 



CHK 
ADJ 


<a 



LUBRICATING THE DRIVE CHAIN 

The drive chain consists of many interacting 
parts. If the drive chain is not maintained prop- 
erly, it will wear out rapidly. Therefore, the drive 
chain should be serviced, especially when the 
motorcycle is used in dusty areas. This motor- 
cycle has a drive chain with small rubber O- 
rings between each side plate. Steam cleaning, 
high-pressure washing, certain solvents, and 
the use of a coarse brush can damage these O- 
rings. Therefore, use only kerosine to clean the 
drive chain. Wipe the drive chain dry and thor- 
oughly lubricate it with engine oil or chain lubri- 
cant that is suitable for O-ring chains. Do not 
use any other lubricants on the drive chain since 
they may contain solvents that could damage 
the O-rings. 



Recommended lubricant 

Engine oil or chain lubricant 
suitable for O-ring chains 



EB304130 

CHECKING AND ADJUSTING THE STEER- 
ING HEAD 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




NOTE: ___ 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 



2. Check: 
•steering head 

Grasp the bottom of the front fork legs and 
gently rock the front fork. 
Looseness/binding ->• Adjust the steering 
head. 



3-47 



CHECKING AND ADJUSTING THE STEERING HEAD 



CHK 
ADJ 


<£ 




3. Remove: 
• upper bracket bolts © 
•front brake fluid reservoir bolt (2) 



4. Loosen: 

•upper bracket pinch bolts © 

• handlebar pinch bolts (2) 
•washer® 

5. Remove: 

• handlebars 

(from the upper bracket) 



6. Remove: 
•steering stem nut© 
•washer© 
•upper bracket (3) 



7. Adjust: 
• steering head 



a. Remove the lock washer ©, the upper ring 
nut (D, and the washer (3). 

b. Loosen the lower ring nut® and then tighten 
it to specification with a ring nut wrench (5). 

NOTE: 

Set the torque wrench at a right angle to the 
steering nut wrench. 




Steering nut wrench 

90890-01403, YU-33975 






Lower ring nut (initial tightening 
torque) 

17Nm(1.7m-kg, 12fMb) 



3-48 



CHECKING AND ADJUSTING THE STEERING HEAD 




CHK 
ADJ 


<a 



c. Loosen the lower ring nut completely, then 
tighten it to specification. 



A WARNING 



Do not overtighten the lower ring nut. 



^ 



\ 



Lower ring nut (final tightening 
torque) 

9 Nm (0.9 nvkg, 6.5 fMb) 



d. Check the steering head for looseness or 
binding by turning the front fork all the way in 
both directions. If any binding is felt, remove 
the lower bracket and check the upper and 
lower bearings. 

Refer to "STEERING HEAD" in chapter 7. 

e. Install the washer®. 

f. Install the upper ring nut (2). 

g. Finger tighten the upper ring nut (2), then 
align the slots of both ring nuts. 

If necessary, hold the lower ring nut and 
tighten the upper ring nut until their slots are 
aligned, 
h. Install the lock washer©. 

NOTE: 

Make sure that the lock washer tabs (a) sit cor- 
rectly in the ring nut slots (b). 




8. Install: 
•steering stem nut 



' upper bracket bolt 



Xl 11 5 Nm (11.5 nvkg, 83 ft»lb) 



13 Nm (1.3 nvkg, 9.4ft»lb) 



■handlebar pinch bolt 

\pl 3 Nm (1 .3 nvkg, 9.4 ft'lbf 



■ upper bracket pinch bolt 

^Xl 23 Nm (2.3 nvkg, 17 it-lb) 



9. Measure: 
•steering head tension 
(with the motorcycle still on the stand) 



NOTE: 

Make sure that all of the cables and wires are 
properly routed. 

a. Point the front wheel straight ahead. 

b. Install a plastic locking tie© loosely around 
the end of the handlebar as shown. 

c. Hook a spring gauge (2) onto the plastic lock- 
ing tie. 



3-49 



CHECKING AND ADJUSTING THE STEERING HEAD/ 

CHECKING THE FRONT FORK 



CHK 
ADJ 


<a 




d. Hold the spring gauge at a 90° angle from 
the handlebar, pull the spring gauge, and re- 
cord the measurement when the handlebar 
starts to turn. 




Steering head tension 

200 ~ 500 g (7.1 ~ 17.6 oz) 



e. Repeat the above procedure on the opposite 
handlebar. 

f. If the steering head tension is out of specifi- 
cation (both handlebars should be within 
specification), remove the upper bracket and 
loosen or tighten the upper ring nut. 

g. Reinstall the upper bracket and measure the 
steering head tension again as described 
above. 

h. Repeat the above procedure until the steer- 
ing head tension is within specification. 

i. Grasp the bottom of the front fork legs and 
gently rock the front fork. 
Looseness or binding -+ Adjust the steering 
head. 




CHECKING THE FRONT FORK 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Check: 

• inner tube© 

Damage/scratches — ► Replace, 
•oil seal® 

Oil leakage -+ Replace. 

3. Hold the motorcycle upright and apply the 
front brake. 

4. Check: 

•front fork operation 
Push down hard on the handlebars several 
times and check if the front fork rebounds 
smoothly. 

Rough movement — ► Repair. 
Refer to "FRONT FORK" in chapter 7. 



3-50 



ADJUSTING THE FRONT FORK LEGS 



CHK 
ADJ 


<a 




ADJUSTING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 



A WARNING 



• Always adjust both front fork legs evenly. 
Uneven adjustment can result in poor han- 
dling and loss of stability. 

•Securely support the motorcycle so that 
there is no danger of it falling over. 

Spring preload 
CAUTION: 



•Grooves are provided to indicate the ad- 
justment position. 

•Never go beyond the maximum or mini- 
mum adjustment positions. 

1. Adjust: 
•spring preload 

a. Turn the adjusting bolt © in direction (§) or 



Direction (a) 



Direction (§) 



Spring preload is 
increased (suspension is 
harder). 



Spring preload is 
decreased (suspension is 
softer). 





















Standarc 


1 








\^ 


Hard 


» 


Soft 


Adjusting 
position 


1 




2 




3 




4 




5 




6 




7 




8 





3-51 



ADJUSTING THE FRONT FORK LEGS 



CHK 
ADJ 


<& 




Rebound damping 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
•rebound damping 

a. Turn the adjusting screw© in direction (Dor 



Direction (D 


Rebound damping is 
increased (suspension is 
harder). 


Direction ® 


Rebound damping is 
decreased (suspension is 
softer). 



Adjusting positions 

Minimum: 9 clicks out* 

Standard: 6 clicks out* 

Maximum: 1 clicks out* 
* from the fully turned-in position 



NOTE: 

Although the number of clicks between the mini- 
mum and maximum settings may vary with 
each individual shock absorber and may not ex- 
actly match these specifications, it is always the 
full damping force range that extends over the 
actual number of clicks. 



Compression damping 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 




1. Adjust: 
•compression damping 



a. Turn the adjusting screw© in direction® or 



Direction (a) 


Compression damping is 
increased (suspension is 
harder). 


Direction (b) 


Compression damping is 
decreased (suspension is 
softer). 



3-52 



ADJUSTING THE FRONT FORK LEGS 



CHK 
ADJ 


<& 



Adjusting positions 
Minimum: 10 clicks out* 
Standard: 6 clicks out* 
Maximum: 1 clicks out* 

* from the fully turned-in position 



NOTE: 

Although the number of clicks between the mi- 
numum and maximum settings may vary with 
each individual shock absorber and may not ex- 
actly match these specifications, it is always the 
full damping force range that extends over the 
actual number of clicks. 



3-53 



ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 



CHK 
ADJ 


<& 



ADJUSTING THE REAR SHOCK ABSORB- 
ER ASSEMBLY 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 




Spring preload 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
•spring preload 

NOTE: 

Adjust the spring preload with the special 
wrench and extension bar included in the own- 
er's tool kit. 



a. Turn the adjusting ring © in direction (a) or 

b. Align the desired position on the adjusting 
ring with the position indicator (2). 



Direction (a) 


Spring preload is 
increased (suspension is 
harder). 


Direction (6) 


Spring preload is 
decreased (suspension is 
softer). 



Adjusting positions 
Minimum: 1 
Standard: 4 
Maximum: 9 



3-54 



ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 




CHK 
ADJ 


<a 



Rebound damping 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 

1. Adjust: 
• rebound damping 

a. Turn the adjusting screw® in direction® or 



Direction (a) 


Rebound damping is 
increased (suspension is 
harder). 


Direction © 


Rebound damping is 
decreased (suspension is 
softer). 



Adjusting positions 
Minimum: 25 clicks out* 
Standard: 9 clicks out* 
Maximum: 1 click out* 

*from the fully turned-in position 



NOTE: 

Although the number of clicks between the mini- 
mum and maximum settings may vary with 
each individual shock absorber and may not ex- 
actly match these specifications, it is always the 
full damping force range that extends over the 
actual number of clicks. 



Compression damping 
CAUTION: 



Never go beyond the maximum or minimum 
adjustment positions. 




1. Adjust: 
•compression damping 



a. Turn the adjusting screw© in direction (a) or 

®. 



Direction (§) 


Compression damping is 
increased (suspension is 
harder). 


Direction (b) 


Compression damping is 
decreased (suspension is 
softer). 



3-55 



ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 



CHK 
ADJ 


<& 



Adjusting positions 
Minimum: 13 clicks out* 
Standard: 7 clicks out* 
Maximum: 1 click out* 

* from the fully turned-in position 



NOTE: 

Although the number of clicks between the mini- 
mum and maximum settings may vary with 
each individual shock absorber and may not ex- 
actly match these specifications, it is always the 
full damping force range that extends over the 
actual number of clicks. 



3-56 



CHECKING THE TIRES 



CHK 
ADJ 


<& 




EB304170 

CHECKING THE TIRES 

The following procedure applies to both of the 
tires. 

1. Measure: 
•tire pressure 
Out of specification -► Regulate. 



A WARNING 



•The tire pressure should only be checked 
and regulated when the tire temperature 
equals the ambient air temperature. 

• The tire pressure and the suspension must 
be adjusted according to the total weight 
(including cargo, rider, passenger and ac- 
cessories) and the anticipated riding 
speed. 

•Operation of an overloaded motorcycle 
could cause tire damage, an accident or an 
injury. 

NEVER OVERLOAD THE MOTORCYCLE. 





Basic weight 
(with oil 
and a full 
fuel tank) 


188 kg 


Maximum 
load* 


187 kg 


Cold tire 
pressure 


Front 


Rear 


Up to 90 kg 
(198 lb) 
load* 


250 kPa 

(2.5 kg/cm 2 , 

36.3 psi) 


250 kPa 

(2.5 kg/cm 2 , 

36.3 psi) 


90 kg (198 lb) 

-maximum 

load* 


250 kPa 

(2.5 kg/cm 2 , 

36.3 psi) 


290 kPa 

(2.9 kg/cm 2 , 

42.1 psi) 


High-speed 
riding 


250 kPa 

(2.5 kg/cm 2 , 

36.3 psi) 


250 kPa 

(2.5 kg/cm 2 , 

36.3 psi) 



* total of cargo, 
ries 



rider, passenger and accesso- 



A WARNING 



It is dangerous to ride with a worn-out tire. 
When the tire tread reaches the wear limit, 
replace the tire immediately. 



3-57 



CHECKING THE TIRES 




I2DI ioo:j 



CHK 
ADJ 


«a 



2. Check: 
•tire surfaces 
Damage/wear 



Replace the tire. 




Minimum tire tread depth 
1.6 mm (0.06 in) 



® Tire tread depth 

(2) Side wall 

(3) Wear indicator 



A WARNING 



• Do not use a tubeless tire on a wheel de- 
signed only for tube tires to avoid tire failure 
and personal injury from sudden deflation. 

• When using a tube tire, be sure to install the 
correct tube. 

•Always replace a new tube tire and a new 
tube as a set. 

•To avoid pinching the tube, make sure that 
the wheel rim band and tube are centered in 
the wheel groove. 

•Patching a punctured tube is not recom- 
mended. If it is absolutely necessary to do so, 
use great care and replace the tube as soon 
as possible with a good quality replacement. 

\E Tire \E Wheel 



Tube wheel 


Tube tire only 


Tubeless wheel 


Tube or tubeless 
tire 



• After extensive tests, the tires listed below 
have been approved by Yamaha Motor Co., 
Ltd. for this model. The front and rear tires 
should always be by the same manufacturer 
and of the same design. No guarantee con- 
cerning handling characteristics can be giv- 
en if a tire combination other than one ap- 
proved by Yamaha is used on this 
motorcycle. 



Front tire 



Manufacturer 


Size 


Model 


BRIDGESTONE 


120/60 ZR1 7 
(55W) 


BT56F-E 


DUNLOP 


120/60 ZR17 
(55W) 


D207F-J 



3-58 



CHECKING THE TIRES/CHECKING THE WHEELS 



Rear tire 



CHK 
ADJ 


<a 



Manufacturer 


Size 


Model 


BRIDGESTONE 


180/55 ZR1 7 
(73W) 


BT56R»E 


DUNLOP 


180/55 ZR1 7 
(73W) 


D207-N 



A WARNING 



New tires have a relatively low grip on the 
road surface until they have been slightly 
worn. Therefore, approximately 100 km 
sould be traveled at normal speed before 
any highspeed riding is done. 




NOTE: 

For tires with a direction of rotation mark ©: 
•Install the tire with the mark pointing in the 

direction of wheel rotation. 
• Align the mark (2) with the valve installation 

point. 



CHECKING THE WHEELS 

The following procedure applies to both of the 
wheels. 
1. Check: 
• wheel 
Damage/out-of-round -f Replace. 



A WARNING 



Never attempt to make any repairs to the 
wheel. 



NOTE: 

After a tire or wheel has been changed or re- 
placed, always balance the wheel. 



3-59 



CHECKING AND LUBRICATING THE CABLES/ 

LUBRICATING THE LEVERS AND PEDALS/ 

LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION 



CHK 
ADJ 


<a 



CHECKING AND LUBRICATING THE 
CABLES 

The following procedure applies to all of the 
cable sheaths and cables. 



A WARNING 



Damaged cable sheaths may cause the 
cable to corrode and interfere with its move- 
ment. Replace damaged cable sheaths and 
cables as soon as possible. 

1. Check: 

• cable sheath 
Damage -► Replace. 

2. Check: 
•cable operation 

Rough movement — ► Lubricate. 



Recommended lubricant 

Engine oil or a suitable cable 
lubricant 



NOTE: 

Hold the cable end upright and pour a few drops 
of lubricant into the cable sheath or use a suit- 
able lubing device. 



LUBRICATING THE LEVERS AND PEDALS 

Lubricate the pivoting point and metal-to-metal 
moving parts of the levers and pedals. 



Recommended lubricant 
Lithium soap base grease 



LUBRICATING THE SIDESTAND 

Lubricate the pivoting point and metal -to- metal 
moving parts of the sidestand. 



Recommended lubricant 
Lithium soap base grease 



LUBRICATING THE REAR SUSPENSION 

Lubricate the pivoting point and metal-to-metal 
moving parts of the rear suspension. 



Recommended lubricant 
Lithium soap base grease 



3-60 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<a 





>jf B««" ; ' | 



ELECTRICAL SYSTEM 

CHECKING AND CHARGING THE BATTERY 



A WARNING 



Batteries generate explosive hydrogen gas 
and contain electrolyte which is made of 
poisonous and highly caustic sulfuric acid. 
Therefore, always follow these preventive 
measures: 

• Wear protective eye gear when handling or 
working near batteries. 

•Charge batteries in a well-ventilated area. 

• Keep batteries away from fire, sparks or 
open flames (e.g., welding equipment, 
lighted cigarettes). 

•DO NOT SMOKE when charging or han- 
dling batteries. 

•KEEP BATTERIES AND ELECTROLYTE 
OUT OF REACH OF CHILDREN. 

•Avoid bodily contact with electrolyte as it 
can cause severe burns or permanent eye 
injury. 

FIRST AID IN CASE OF BODILY CONTACT: 

EXTERNAL 

•Skin - Wash with water 

• Eyes - Flush with water for 1 5 minutes and 
get immediate medical attention. 

INTERNAL 

• Drink large quantities of water or milk fol- 
lowed with milk of magnesia, beaten egg or 
vegetable oil. Get immediate medical 
attention. 



CAUTION: 



•This is a sealed battery. Never remove the 
sealing caps because the balance between 
cells will not be maintained and battery 
performance will deteriorate. 

•Charging time, charging amperage and 
charging voltage for an MF battery are dif- 
ferent from those of conventional batter- 
ies. The MF battery should be charged as 
explained in the charging method illustra- 
tions. If the battery is overcharged, the 
electrolyte level will drop considerably. 
Therefore, take special care when charg- 
ing the battery. 



3-61 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<& 



NOTE: 

Since MF batteries are sealed, it is not possible 
to check the charge state of the battery by mea- 
suring the specific gravity of the electrolyte. 
Therefore, the charge of the battery has to be 
checked by measuring the voltage at the battery 
terminals. 














| 12.8V | 






Ql 




18550601 



1. Remove: 

• rider seat 

Refer to "SEATS". 

2. Disconnect: 

• battery leads 

(from the battery terminals) 

CAUTION: 



First, disconnect the negative lead (2), then 
the positive lead©. 



3. Remove: 
• battery 

4. Measure: 
•battery charge 

a. Connect a digital voltmeter to the battery ter- 
minals. 



Tester positive probe -+ battery positive 
terminal 

Tester negative probe -+ battery nega- 
tive terminal 



Relationship between the open-circuit voltage 
and the charging time at 20°C 




5 6.5 10 

Charging time (hours) 

These values vary with the temperature, the condition of 
the battery plates, and the electrolyte level. 



NOTE: 

•The charge state of an MF battery can be 
checked by measuring its open-circuit voltage 
(i.e., the voltage when the positive terminal is 
disconnected). 

• No charging is necessary when the open-cir- 
cuit voltage equals or exceeds 12.8 V. 

b. Check the charge of the battery, as shown in 

the charts and the following example. 
Example 

Open-circuit voltage = 12.0 V 
Charging time = 6.5 hours 
Charge of the battery = 20 ~ 30% 



3-62 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<& 



c 

to 17 
en 

2 16 
o 
> 15 

I 14 
"V 13 

|12 
O 11 


)hargin 


g 

Ambient temperature 20°C 






















































































































o 10 20 30 40 so 60 Time (minutes) 
1"^ Check the open-circuit 
voltage. 



14 
> 13 

CD 
CO 

> 

H 11 

"o 

1 10 

o 








Ambient 

temperature 

20°C 












































100 75 50 30 25 20 
Charging condition of the battery (%) 



5. Charge: 
• battery 
(refer to the appropriate charging method il- 
lustration) 



A WARNING 



Do not quick charge a battery. 



CAUTION: 



• Never remove the MF battery sealing caps. 
•Do not use a high-rate battery charger 

since it forces a high-amperage current 
into the battery quickly and can cause bat- 
tery overheating and battery plate damage. 

• If it is impossible to regulate the charging 
current on the battery charger, be careful 
not to overcharge the battery. 

•When charging a battery, be sure to re- 
move it from the motorcycle. (If charging 
has to be done with the battery mounted on 
the motorcycle, disconnect the negative 
lead from the battery terminal.) 

•To reduce the chance of sparks, do not 
plug in the battery charger until the battery 
charger leads are connected to the battery. 

• Before removing the battery charger lead 
clips from the battery terminals, be sure to 
turn off the battery charger. 

•Make sure that the battery charger lead 
clips are in full contact with the battery ter- 
minal and that they are not shorted. A cor- 
roded battery charger lead clip may gener- 
ate heat in the contact area and a weak clip 
spring may cause sparks. 

• If the battery becomes hot to the touch at 
any time during the charging process, dis- 
connect the battery charger and let the bat- 
tery cool before reconnecting it. Hot batter- 
ies can explode! 

•As shown in the following illustration, the 
open-circuit voltage of an MF battery stabi- 
lizes about 30 minutes after charging has 
been completed. Therefore, wait 30 min- 
utes after charging is completed before 
measuring the open-circuit voltage. 



3-63 



CHECKING AND CHARGING THE BATTERY 



CHK 
ADJ 


<a 



Charging method using a variable-voltage charger 



Charger 



Ammeter 




Measure the open-circuit 
voltage prior to charging. 



I 



NOTE: 

Leave the battery unused for more than 
30 minutes before measuring its open- 
circuit voltage. 



Connect a charger and am- 
meter to the battery and 
start charging. 



Is the amperage higher 
than the standard charging 
amperage written on the 
battery? 



NOTE: 

Set the charging voltage to 16 - 17 V. 
(If the charging voltage is lower, charg- 
ing will be insufficient, if it is higher, the 
battery will be over-charged.) 



NO 



Adjust the charging voltage to 
20 ~ 25 V. 



Adjust the voltage to obtain the 
standard charging amperage. 



YES 



Monitor the amperage for 3 ~ 
5 minutes. Is the standard 
charging amperage exceed- 
ed? 



Set the timer to the charging 
time determined by the open- 
circuit voltage. 

Refer to "CHECKING AND 
CHARGING THE BATTERY". 



NO 



If the amperage does not 
exceed the standard charg- 
ing amperage after 5 min- 
utes, replace the battery. 



If the required charging time exceeds 5 hours, it is advisable to check 
the charging amperage after 5 hours. If there is any change in the am- 
perage, readjust the voltage to obtain the standard charging amper- 
age. 



Leave the battery unused for more than 30 minutes before measur- 
ing its open-circuit voltage. 
12.8 V -► Charging is complete. 
12.0 ~ 12.7 V -+ Recharging is required. 
Under 12.0 V -+ Replace the battery. 



3-64 



CHECKING AND CHARGING THE BATTERY 



Charging method using a constant-voltage charger 



CHK 
ADJ 


<& 



Measure the open-circuit 
voltage prior to charging. 



NOTE: 

Leave the battery unused for more than 
30 minutes before measuring its open- 
circuit voltage. 



Connect a charger and am- 
meter to the battery and 
start charging. 



YES 



Is the amperage higher 
than the standard charging 
amperage written on the 
battery? 



NO 



Charge the battery until the charging 
voltage reaches 1 5 V. 



NOTE: 

Set the charging time to a maximum of 
20 hours. 



This type of battery charger cannot 
charge an MF battery. A variable- 
voltage charger is recommended. 



Charger 



Leave the battery unused for more 
than 30 minutes before measuring its 
open-circuit voltage. 
12.8 V -v Charging is complete. 
12.0 ~ 12.7 V -> Recharging is re- 
quired. 
Under 1 2.0 V -+ Replace the battery. 



Ammeter 



CAUTION: 

Constant amperage chargers are not 
suitable for charging MF batteries. 




3-65 



CHECKING AND CHARGING THE BATTERY/ 

CHECKING THE FUSES 



6. Install: 

• battery 

7. Connect: 

• battery leads 

(to the battery terminals) 



CHK 
ADJ 


<a 




CAUTION: 



First, connect the positive lead ®, then the 
negative lead (2). 

8. Check: 
•battery terminals 

Dirt -+ Clean with a wire brush. 
Loose connection -+ Connect properly. 

9. Lubricate: 
•battery terminals 



Recommended lubricant 
Dielectric grease 



10. Install: 
• rider seat 
Refer to "SEATS". 

EB305040 

CHECKING THE FUSES 

The following procedure applies to all of the 
fuses. 

CAUTION: 



To avoid a short circuit, always set the main 
switch to "OFF" when checking or replacing 
a fuse. 

1. Remove: 
• rider seat 

Refer to "SEATS". 

2. Check: 
•continuity 

a. Connect the pocket tester to the fuse and 
check the continuity. 

NOTE: 

Set the pocket tester selector to "Q x 1 ". 



y- 



Pocket tester 

90890-03112, YU-031 12 



b. If the pocket tester indicates "°°", replace the 
fuse. 



3-66 



CHECKING THE FUSES 



CHK 
ADJ 


<& 




3. Replace: 
•blown fuse 



a. Set the main switch to "OFF". 

b. Install a new fuse of the correct amperage. 

c. Set the main switch to "ON" and verify if the 
electrical circuit is operational. 

d. If the fuse immediately blows again, check 
the electrical circuit. 



Item 


Amperage 


Q'ty 


Main fuse 


30 A 




Headlight 
fuse 


20 A 




Signaling 
system fuse 


20 A 




Ignition 
fuse 


15A 




Radiator 

fan motor 

fuse 


7.5 A 




Backup fuse 
(odometer) 


7.5 A 





A WARNING 



Never use a fuse with an amperage other 
than that specified. Improvising or using a 
fuse with the wrong amperage rating may 
cause extensive damage to the electrical 
system, cause the lighting and ignition sys- 
tems to malfunction and could possibly 
cause a fire. 

4. Install: 
• rider seat 
Refer to "SEATS". 



3-67 



REPLACING THE HEADLIGHT BULBS 



CHK 
ADJ 


<a 




REPLACING THE HEADLIGHT BULBS 

The following procedure applies to both of the 
headlight bulbs. 
1. Disconnect: 

• headlight coupler © 

• headlight bulb holder cover (2) 



2. Detach: 

•headlight bulb holder© 

3. Remove: 
•headlight bulb (2) 



A WARNING 



Since the headlight bulb gets extremely hot, 
keep flammable products and your hands 
away from the bulb until it has cooled down. 

4. Install: 

•headlight bulb ISEM 
Secure the new headlight bulb with the head- 
light bulb holder. 

CAUTION: 



Avoid touching the glass part of the head- 
light bulb to keep it free from oil, otherwise 
the transparency of the glass, the life of the 
bulb and the luminous flux will be adversely 
affected. If the headlight bulb gets soiled, 
thoroughly clean it with a cloth moistened 
with alcohol or lacquer thinner. 

5. Attach: 
•headlight bulb holder 

6. Install: 

• headlight bulb holder cover 

7. Connect: 
•headlight coupler 



3-68 



ADJUSTING THE HEADLIGHT BEAMS 




CHK 
ADJ 


<a 



ADJUSTING THE HEADLIGHT BEAMS 

The following procedure applies to both of the 
headlights. 
1. Adjust: 
•headlight beam (vertically) 

a. Turn the adjusting screw® in direction® or 



Direction (a) 


Headlight beams is raised. 


Direction (6) 


Headlight beams is low- 
ered. 




2. Adjust: 
•headlight beam (horizontally) 

a. Turn the adjusting knob ® in direction @ or 

®. 
Left headlight 



Direction (a) 


Headlight beam moves 
to the right. 


Direction © 


Headlight beams moves 
to the left. 



Right headlight 



Direction (g) 


Headlight beam moves 
to the left. 


Direction (g) 


Headlight beam moves 
to the right. 



3-69 



ENG 





CHAPTER 4. 
ENGINE OVERHAUL 

ENGINE 4.1 

DRIVE SPROCKET 4-1 

EXHAUST ASSEMBLY 4-2 

LEAD AND HOSES 4-3 

ENGINE 4-5 

INSTALLING THE ENGINE 4-6 

CAMSHAFTS 4-7 

CYLINDER HEAD COVER 4-7 

CAMCHAFTS 4-8 

REMOVING THE CAMSHAFTS 4-10 

CHECKING THE CAMSHAFTS 4-11 

CHECKING THE CAMSHAFT SPROCKETS 

AND TIMING CHAIN GUIDES 4-12 

CHECKING THE TIMING CHAIN TENSIONER 4-13 

INSTALLING THE CAMSHAFTS 4-14 

CYLINDER HEAD 4-17 

REMOVING THE CYLINDER HEAD 4-18 

CHECKING THE CYLINDER HEAD 4-18 

INSTALLING THE CYLINDER HEAD 4-19 

VALVES AND VALVE SPRINGS 4-20 

REMOVING THE VALVES 4-22 

CHECKING THE VALVES AND VALVE GUIDES 4-23 

CHECKING THE VALVE SEATS 4-25 

CHECKING THE VALVE SPRINGS 4-27 

CHECKING THE VALVE LIFTERS 4-28 

INSTALLING THE VALVES 4-28 

PICKUP COIL AND PICKUP COIL ROTOR 4-31 

REMOVING THE PICKUP COIL ROTOR 4-33 

INSTALLING THE PICKUP COIL ROTOR 4-33 

STARTER CLUTCH AND GENERATOR 4-35 

REMOVING THE GENERATOR 4-37 

REMOVING THE STARTER CLUTCH 4-38 

CHECKING THE STARTER CLUTCH 4-38 

INSTALLING THE STARTER CLUTCH 4-39 

INSTALLING THE GENERATOR 4-39 

SHIFT SHAFT 4 . 4 

CHECKING THE SHIFT SHAFT 4-42 

CHECKING THE STOPPER LEVER 4.42 

INSTALLING THE SHIFT SHAFT 4.42 

CLUTCH 4.43 

CLUTCH COVER 4.43 



4* 



ENG % 



« 



CLUTCH 4-46 

REMOVING THE CLUTCH 4-48 

CHECKING THE FRICTION PLATES 4-48 

CHECKING THE CLUTCH PLATES 4-49 

CHECKING THE CLUTCH SPRINGS 4-49 

CHECKING THE CLUTCH HOUSING 4-49 

CHECKING THE CLUTCH BOSS 4-50 

CHECKING THE PRESSURE PLATE 4-50 

CHECKING THE PULL LEVER SHAFT AND PULL ROD 4-50 

INSTALLING THE CLUTCH 4-51 

OIL PAN AND OIL PUMP 4-53 

REMOVING THE OIL PAN 4-56 

CHECKING THE OIL PUMP 4-56 

CHECKING THE RELIEF VALVE 4-57 

CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 4-57 

CHECKING THE OIL STRAINER 4-57 

CHECKING THE OIL NOZZLES 4-57 

ASSEMBLING THE OIL PUMP 4-57 

INSTALLING THE OIL PUMP 4-58 

INSTALLING THE OIL STRAINER 4-58 

INSTALLING THE OIL PAN 4-58 

CRANKCASE 4-59 

OIL BAFFLE PLATES AND OIL FILTER BOLT 4-61 

DISASSEMBLING THE CRANKCASE 4-62 

CHECKING THE CRANKCASE 4-63 

CHECKING THE BEARINGS AND OIL SEALS 4-63 

CHECKING THE SPROCKETS AND CHAINS 4-63 

ASSEMBLING THE CRANKCASE 4-64 

CONNECTING RODS AND PISTONS 4-66 

REMOVING THE CONNECTING RODS AND PISTONS 4-68 

CHECKING THE CYLINDERS AND PISTONS 4-69 

CHECKING THE PISTON RINGS 4-70 

CHECKING THE PISTON PINS 4-71 

CHECKING THE BIG END BEARINGS 4-72 

INSTALLING THE PISTONS AND CONNECTING RODS 4-74 

CRANKSHAFT 4-78 

REMOVING THE CRANKSHAFT 4-79 

CHECKING THE CRANKSHAFT 4-79 

CHECKING THE CRANKSHAFT JOURNAL BEARINGS 4-79 

INSTALLING THE CRANKSHAFT 4-82 

TRANSMISSION 4-83 

REMOVING THE TRANSMISSION 4-89 

CHECKING THE SHIFT FORKS 4-89 

CHECKING THE SHIFT DRUM ASSEMBLY 4-90 

CHECKING THE TRANSMISSION 4-90 

INSTALLING THE TRANSMISSION 4-91 



ENGINE 



ENG 



ENGINE OVERHAUL 



ENGINE 

DRIVE SPROCKET 



Order 



1 
2 
3 
4 
5 
6 
7 



Job/Part 



Removing the drive sprocket 

Reserve tank 

Locknut 

Shift rod 

Shift arm 

Drive sprocket cover 

Nut 

Lock washer 

Drive sprocket 



Q'ty 



Remarks 



V 




Remove the parts in the order listed. 
Refer to "CHANGING THE COOLANT" 



For installation reverse the remove 
procedure. 



4-1 



ENGINE 



ENG 



4k 



m 



EXHAUST ASSEMBLY 



38 Nm (3.8 nvkg, 27 ft«lb) 




20 Nm (2.0 m»kg, 14 ft«lb) 



20 Nm (2.0 nvkg, 14ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the exhaust assembly 

Bottom cowling and side cowlings 
Coolant 




Remove the parts in the order listed. 

Refer to "COWLINGS" in chapter 3 

Drain. 

Refer to "CHANGING THE COOLANT' in 


1 


Radiator assembly 
Muffler 


1 


chapter 3. 

Refer to "RADIATOR" in chapter 5. 


2 
3 


Exhaust pipe assembly 
Exhaust pipe gasket 


1 
4 


For installation reverse the removal 
procedure. 



4-2 



ENGINE 



ENG 



Id 



LEADS AND HOSES 




Order 


Job/Part 


Q'ty 


Remarks 




Disconnecting the leads and hoses 

Fuel tank 




Disconnect the parts in the order listed. 
Refer to "FUEL TANK" in chapter 3. 




Air filter case 




Refer to "AIR FILTER CASE AND 




Carburetor assembly and joints 
Engine oil and oil filter cartridge 




IGNITION COILS" in chapter 3. 

Refer to "CARBURETORS" in chapter 6. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 




Oil cooler 




in chapter 3. 

Refer to "OIL COOLER" in chapter 5. 



4-3 



ENGINE 



ENG 



% 




Order 


Job/Part 


Q'ty 


Remarks 


1 
2 

3 
4 
5 
6 
7 
8 


Battery negative lead 
Battery positive lead 

Startor coil assembly coupler 

Pickup coil coupler 

Engine earth 

Clutch wire and holder 

Crankcase breather hose 

Separator 


1 
1 


CAUTION: 


First, disconect the negative lead, then 
the positive lead. 


For connecting reverse the discomecting 
procedure. 



4-4 



ENGINE 



ENG 



%1 



ENGINE 



24 Nm (2.4 nvkg, 17ft»lb)| 1 



45 Nm (4.5 nvkg, 33 ft'lb) 




55 Nm (5.5 nvkg, 
40 ft'lb) 




55 Nm (5.5 nvkg, 
40 ftHb) 



38 Nm (3.8 nvkg, 
27 ft'lb) 



13 Nm (1.3 nvkg, 9.4 ft»lb) 



24 Nm (2.4 nvkg, 17 ft'lb) 



7 Nm (0.7 nvkg, 5.1 ft'lb) 



Order 



1 
2 
3 
4 
5 
6 
7 



Job/Part 



Removing the engine 



Pinch bolts 

Button head bolts 

Collars 

Front mounting bolts 

Collars 

Rear mounting bolts 

Engine mounting adjust bolts 



Q'ty 



4 
2 
2 
2 
2 
2 
2 



Remarks 



Remove The Parts In The Order Listed. 
NOTE: 



Place a suitable stand under the frame and 
engine. 



Refer to "INSTALLING THE ENGINE". 



NOTE: 

Use the point shaft wrench to loosen the 
engine mounting adjust bolt. 



For Installation, Reverse The Removal 
Procedure. 



4-5 




ENGINE 



ENG 



m 



INSTALLING THE ENGINE 

1. Install: 
•engine mounting adjust bolts© 
•rear mounting bolts© 
•self-locking nuts® 
•collars® 
•front mounting bolts (5) 

• collars (6) 

• button head bolts (7) 

• pinch bolts® 

NOTE: 



• Lubricate the rear mounting bolt threads with 
lithium soap base grease. 

• Do not fully tighten the nuts and bolts. 



2. Tighten: 
•self-locking nut 



45 Nm (4.5 nvkg, 33 ft'lb) 



•front mounting bolts 
> button head bolt 



XI 55 Nm (5.5 m»kg, 40 ft'lb) 



• pinch bolt M8 
M6 
•engine adjusting bolts 

NOTE: 



\ 


38 Nm (3.8 


nvkg, 


27 ft 


•lb) 


\ 


24 Nm (2.4 nvkg, 


17ft 


•lb) 


\ 


13Nm(1.3 


nvkg, 


9.4 ft 


•lb) 



Use the pivot shaft wrench © to tighten the en- 
gine mounting adjust bolt to finger tightness. 




Pivot shaft wrench 
90890-01471 



3. Install: 
•drive sprocket 

4. Install: 

• drive sprocket cover 



70 Nm (7.0 nvkg, 51 ft'lb) 



10 Nm (1.0 nvkg, 7.2 ft«lb) 



NOTE: 

Refer to "CABLE ROUTING" in chapter 2. 



5. Install: 
• shift arm © 

NOTE: 



10 Nm (1.0 nvkg, 7.2 ft'lb) 



Align the punch mark ® in the shift shaft with 
the slot in the shift arm. 



4-6 



CAMSHAFTS 



ENG 



V 



CAMSHAFTS 

CYLINDER HEAD COVER 



13Nm(1.3m»kg, 9.4ft»lb) 



10Nm(1.0m»kg, 7.2 ft«lb) 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the cylinder head cover 




Remove the parts in the order listed. 




Carburetor assembly 




Refer to "CARBURETORS" in chapter 6. 




Radiator assembly 




Refer to "RADIATOR" in chapter 5. 


1 


Spark plugs 


4 




2 


Cylinder head cover 


1 




3 


Cylinder head cover gasket 


1 




4 


Timing chain guide (top side) 


1 


For installation reverse the removal 
procedure. 



4-7 



CAMSHAFTS 



ENG 



%1 



CAMSHAFTS 



10Nm(1.0m«kg, 7.2 ft»lb) 



10Nm(1.0m»kg, 7.2ft«lb) 



12Nm(1.2nrkg, 
8.7 ft-lb) 




24 Nm (2.4 nvkg, 17ft»lb) 



Order 


Job/Part 


Q'ty 


Remarks 


1 
2 
3 
4 
5 

6 

7 
8 


Removing the camshafts 

Pickup coil rotor cover 

Timing chain tensioner 
Timing chain tensioner gasket 
Camshaft cap 
Camshaft cap gasket 
Dowel pin 

Intake camshaft 

Exahust camshaft 

Timing chain guide (exhaust side) 


1 _ 
1 

1 - 
4 - 
2 

1 - 
1 
1 - 


Remove the parts in the order listed. 
Refer to "PICKUP COIL AND PICK UP 
COIL COVER". 

" Refer to "REMOVING/ INSTALLING 
THE CAMSHAFTS". 
NOTE- 


During removal, the dowel pins may still 
be connected to the camshaft cap. 


" Refer to "REMOVING/INSTALLING 
. THE CAMSHAFT". 



4-8 



CAMSHAFTS 



ENG 



% 



10Nm(1.0m«kg, 7.2 ft»lb) 



10Nm(1.0nrkg, 7.2ft»lb) 



12Nm(1.2 m«kg, 
8.7 ft'lb) 




24 Nm (2.4 nvkg, 17ft»lb) 



Order 



9 
10 
11 
12 



Job/Part 



Intake camshaft sproket 

Exhaust camshaft sproket 

Pin 

Timing chain guide (intake side) 



Q'ty 



Remarks 



Refer to "INSTALLING THE 
CAMSHAFTS". 

For installation reverse the removal 
procedure. 



4-9 



CAMSHAFTS 



ENG 



%1 




REMOVING THE CAMSHAFTS 

1. Align: 
•TDC mark on the pickup coil rotor (with the 
crankcase mating surface) 

a. Turn the crankshaft clockwise. 

b. When piston #1 is at TDC on the compres- 
sion stroke, align the mark (a) on the pickup 
coil rotor with the crankcase mating surface 
©. 

NOTE: 

TDC on the compression stroke can be found 
when the camshaft lobes are turned away from 
each other. 



2. Remove: 

•timing chain tensioner 

3. Remove: 

• camshaft cap 
•dowel pins 

CAUTION: 



To prevent damage to the cylinder head, 
camshafts or camshaft cap, loosen the cam- 
shaft cap bolts in stages and in a crisscross 
pattern, working from the outside in. 




4. Remove: 

• intake camshaft © 

• exhaust camshaft (2) 

NOTE: 



To prevent the timing chain from falling into the 
crankcase, fasten it with a wire (3). 

5. Remove: 
•timing chain guide (exhaust side) 



4-10 




V 






A N - 


IliriMHE 




CAMSHAFTS 



ENG 



M 



CHECKING THE CAMSHAFTS 

1. Check: 

• camshaft lobes 

Blue discoloration/pitting/scratches -+ Re- 
place the camshaft. 

2. Measure: 

•camshaft lobe dimensions (a) and (6) 
Out of specification -+ Replace the cam- 
shaft. 




Camshaft lobe dimensions limit 

Intake camshaft 
@ 33.0 mm (1.3 in) 
© 25.09 mm (0.99 in) 

Exhaust camshaft 
@ 32.50 mm (1.28 in) 
® 25.02 mm (0.99 in) 



Measure: 
•camshaft runout 
Out of specification 



Replace. 




Max. camshaft runout 
0.06 mm (0.0024 in) 




4. Measure: 
• camshaft-journal-to-camshaft-cap clear- 
ance 

Out of specification -+ Measure the cam- 
shaft journal diameter. 




Camshaft-journal-to-camshaftcap 
clearance 

0.020 ~ 0.054 mm 

(0.0008 ~ 0.0021 in) 

<Limit>: 0.08 mm (0.0031 in) 



a. Install the camshaft into the cylinder head 
(without the dowel pins and camshaft caps). 

b. Position a strip of Plastigauge® © onto the 
camshaft journal as shown. 

c. Install the dowel pins and camshaft caps. 



4-11 




CAMSHAFTS 




NOTE: 

• Tighten the camshaft cap bolts in stages and in 
a crisscross pattern, working from the inner 
caps out. 

• Do not turn the camshaft when measuring the 
camshaft-journal-to-camshaft-cap clearance 
with the Plastigauge®. 



V 



■\ 



Camshaft cap bolt 

10Nm(1.0rtvkg, 7.2 fWb) 



d. Remove the camshaft caps and then mea- 
sure the width of the Plastigauge® ©. 




5. Measure: 
• camshaft journal diameter® 
Out of specification -► Replace the cam- 
shaft. 

Within specification -► Replace the cylinder 
head and the camshaft caps as a set. 




Camshaft journal diameter 
22.967 ~ 22.980 mm 
(0.9042 ~ 0.9047 in) 



CHECKING THE CAMSHAFT SPROCKETS, 
AND TIMING CHAIN GUIDES 

The following procedure applies to all of the 
camshaft sprockets and timing chain guides. 



4-12 



CAMSHAFTS 



ENG 



m 




1. Check: 

• camshaft sprocket 
More than 1 I A tooth wear® _► Replace the 
camshaft sprockets and the timing chain as a 
set. 

® 1 1 A tooth 

(6) Correct 

© Timing chain roller 

(2) Camshaft sprocket 

2. Check: 

•timing chain guide (exhaust side) © 
•timing chain guide (intake side) (2) 
•timing chain guide (top side) (3) 

Damage/wear -+ Replace the defective 

part(-s). 



CHECKING THE TIMING CHAIN TENSIONER 

1. Check: 
•timing chain tensioner 
Cracks/damage/rough movement -+ Re- 
place. 

a. Lightly press the timing chain tensioner rod 
into the timing chain tensioner housing by 
hand. 

NOTE: - 

While pressing the timing chain tensioner rod, 
wind it clockwise with a thin screwdriver© until 
it stops. 



b. Remove the screwdriver and slowly release 
the timing chain tensioner rod. 

c. Make sure that the timing chain tensioner rod 
comes out of the timing chain tensioner 
housing smoothly. If there is rough move- 
ment, replace the timing chain tensioner. 



4-13 



CAMSHAFTS 



ENG 



% 




INSTALLING THE CAMSHAFTS 

1. Install: 

•timing chain guide (intake side) 
•timing chain guide (exhaust side) 

2. Install: 

• intake camshaft sprocket 



24 Nm (2.4 nvkg, 17fMb) 



■exhaust camshaft sprocket 



24 Nm (2.4 nvkg, 17 ft«lb) 



NOTE: 

Cam sprocket timing mark is outside and align 
the cam sprocket hole to camshaft hole. 

3. Install: 
•exhaust camshaft 

• intake camshaft 
•camshaft cap gasket 

• camshaft cap 

a. Turn the crankshaft clockwise. 

b. When piston #1 is at TDC on the compres- 
sion stroke, align the (a) mark on the pickup 
coil rotor with the crankcase mating surface 

®. 

c. Install the timing chain onto both camshaft 
sprockets and then install the camshaft 
sprockets onto the camshafts. 

CAUTION: 



Do not turn the crankshaft when installing 
the camshaft to avoid damage or improper 
valve timing. 

d. Install the exhaust and intake camshaft cap. 



^ 



Camshaft cap bolt 

10Nm(1.0m«kg, 7.2 ft-lb) 



NOTE: 

Make sure that the camshaft sprocket timing 

marks © are aligned with the cylinder head 

edge® 

Out of alignment — ► Reinstall. 

e. Remove the wire from the timing chain. 



4-14 




CAMSHAFTS 



ENG 



% 



4. Install: 
• timing chain tensioner 



a. Lightly press the timing chain tensioner rod 
into the timing chain tensioner housing by 
hand. 

b. While pressing the timing chain tensioner 
rod, wind it clockwise with a thin screwdriver 
CD until if stops. 

C. With the screwdriver still inserted into the 
timing chain tensioner, install the timing 
chain tensioner (2), gasket, and float cham- 
ber air vent hose holder® onto the cylinder 
block. Then, tighten the timing chain tension- 
er bolts (4) to the specified torque. 



A WARNING 



Always use a new gasket. 



NOTE: 

The "UP" mark on the timing chain tensioner 
should face up. 



X 



\ 



Timing chain tensioner bolt 
12Nm(1.2nrkg, 8.7 fMb) 



d. Remove the screwdriver, make sure that the 
timing chain tensioner rod releases, and 
tighten the cap bolt to the specified torque. 



X 



*\ 



Cap bolt 

10Nm(1.0m«kg, 7.2 fMb) 



5. Turn: 
•crankshaft (several turns counterclockwise) 



4-15 



CAMSHAFTS 



ENG 



M 




6. Check: 

•TDC mark® 
Make sure that the TDC mark is aligned with 
the crankcase mating surface ©. 

•camshaft sprocket timing mark© 
Make sure that the camshaft sprocket timing 
mark is aligned with the cylinder head edge 

® 

Out of alignment -+• Adjust. 

Refer to the installation steps above. 



7. Measure: 
•valve clearance 
Out of specification -* Adjust. 
Refer to "ADJUSTING THE VALVE CLEAR- 
ANCE" in chapter 3. 



8. Install: 
•cylinder head cover gasket 
•cylinder head cover 

NOTE: 



•Apply bond TB1541 onto the mating surfaces 

of the cylinder head cover and cylinder head 

cover gasket. 
« Apply bond 1 21 5B onto the mating surfaces of 

the cylinder head cover gasket and cylinder 

head. 
• Tighten the cylinder head cover bolts in stages 

and in a crisscross pattern. 



4-16 



CYLINDER HEAD 



10Nm(1.0nvkg, 7.2 ft'lb) 



CYLINDER HEAD 



ENG 


wB 



51 Nm (5.1 m«kg, 37 ft'lb) 



-HIIE 




Order 



2 
3 



Job/Part 



Removing the cylinder head 

Intake and exhaust camshafts 
Water hose 
Temp senser lead 
Front mounting bolt 
Cylinder head 

Cylinder head gasket 
Dowel pin 



Q'ty 



1 
2 



Remarks 



Remove the parts in the order listed. 

Refer to "CAMSHAFTS". 

Disconnect 

Disconnect 

Refer to "ENGINE". 

Refer to "REMOVING/INSTALLING THE 

CYLINDER HEAD". 



For installation reverse the removal 
procedure. 



4-17 



CYLINDER HEAD 




ENG 



m 



REMOVING THE CYLINDER HEAD 

1. Remove: 
•cylinder head bolts 
•cylinder head 

NOTE: 



Loosen each bolt and nut 1 /2 of a turn at a time, 
in stages and in a crisscross pattern. After all of 
the bolts and nuts are fully loosened, remove 
them. 



CHECKING THE CYLINDER HEAD 

1. Eliminate: 

•combustion chamber carbon deposits (with 
a rounded scraper) 

NOTE: 

Do not use a sharp instrument to avoid damag- 
ing or scratching: 
•spark plug bore threads 
• valve seats 

2. Check: 
•cylinder head 

Damage/scratches -► Replace, 
•cylinder head water jacket 
Mineral deposits/rust — ► Eliminate. 




3. Measure: 
•cylinder head warpage 
Out of specification — ► Resurface the cylin- 
der head. 




Max. cylinder head warpage 
0.05 mm (0.002 in) 



a. Place a straightedge © and a thickness 
gauge (2) across the cylinder head. 

b. Measure the warpage. 

c. If the limited in exceeded, resurface the cyl- 
inder head as follows. 



4-18 



CYLINDER HEAD 



ENG 



m 



d. Place a 400 ~ 600 grit wet sandpaper on the 
surface plate and resurface the cylinder 
head using a figure-eight sanding pattern. 

NOTE: _ 

To ensure an even surface, rotate the cylinder 
head several times. 



INSTALLING THE CYLINDER HEAD 

1. Install: 
•cylinder head gasket 
•cylinder head 

•cylinder headbolt 

(M 1 0) |XI 51 Nm (5.1 nvkg, 37 ft«lb) 
(M6)| X1 10 Mm (1.0 nrkg, 7.2 ft»"ib) 



NOTE: 

•Lubricate the cylinder head nuts with engine 

oil. 
• Tighten the cylinder head nuts and bolts in two 

stages and in a crisscross pattern. 



4-19 



VALVES AND VALVE SPRINGS 



ENG 



m 



VALVES AND VALVE SPRINGS 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the valves and valve 




Remove the parts in the order listed. 




springs 








Cylinder head 




Refer to "CYLINDER HEAD". 


1 


Intake valve lifter 


8 - 




2 


Intake valve pad 


8 




3 


Intake valve cotter 


16 




4 


Intake valve upper spring seat 


8 




5 


Intake valve spring outer 


8 


Refer to "REMOVING/INSTALLING 


6 


Intake valve spring inner 


8 


THE VALVES". 


7 


Intake valve oil seal 


8 




8 


Intake valve lower spring seat 


8 




9 


Intake valve 


8 




10 


Intake valve guide 


8 - 





4-20 



VALVES AND VALVE SPRINGS 



ENG 



V 




Order 


Job/Part 


Q'ty 


Remarks 


11 


Exhaust valve lifter 


8 - 




12 


Exhaust valve pad 


8 




13 


Exhaust valve cotter 


16 




14 


Exhaust valve upper spring seat 


8 


Refer to "REMOVING/INSTALLING THE 


15 


Exhaust valve spring 


8 


VALVES". 


16 


Exhaust valve oil seal 


8 - 




17 


Exhaust valve lower spring seat 


8 




18 


Exhaust valve 


8 




19 


Exhaust valve guide 


8 


For installation, reverse the removal 
procedure. 



4-21 



VALVES AND VALVE SPRINGS 



ENG 



m 



REMOVING THE VALVES 

The following procedure applies to all of the 
valves and related components. 

NOTE: 

Before removing the internal parts of the cylin- 
der head (e.g., valves, valve springs, valve 
seats), make sure that the valves properly seal. 




1. Remove: 
•valve lifter® 
•valve pad (2) 

NOTE: 



Make a note of the position of each valve lifter 
and valve pad so that they can be reinstalled in 
their original place. 



2. Check: 
•valve 
(for leakage) 

Leakage at the valve seat -* Check the valve 
face, valve seat, and valve seat width. 
Refer to "CHECKING THE VALVE SEATS". 

a. Pour a clean solvent @ into the intake and 
exhaust ports. 

b. Check that the valves properly seal. 

NOTE: 

There should be no leakage at the valve seat 

(D. 



4-22 



VALVES AND VALVE SPRINGS 




ENG 



to 



3. Remove: 
•valve cotters® 

NOTE: 



Remove the valve cotters by compressing the 
valve spring with the valve spring compressor 
(D and attachment®. 




Valve spring compressor 
90890-04019, YM-0401 9 

Attachment 

90890-04114, YM-01 253-1 





4. Remove: 
•upper spring seat© 
•valve spring outer (2) 
•valve spring inner (intake only) 
•valve® 
•oil seal© 
• lower spring seat (6) 

NOTE: 



Identify the position of each part very carefully 
so that it can be reinstalled in its original place. 

EASO0239 

CHECKING THE VALVES AND VALVE 
GUIDES 

The following procedure applies to all of the 
valves and valve guides. 
1. Measure: 
• valve-stem-to-valve-guide clearance 



Valve-stem-to-valve-guide clearance = 
Valve guide inside diameter ® - 
Valve stem diameter (6) 



Out of specification 
guide. 



Replace the valve 



7* 


Valve-stem-to-valve-guide clea- 


'"K 


rance 




Intake 


0.010 ~ 0.037 mm 


(0.0004 ~ 0.0015 in) 


<Limit> : 0.08 mm (0.0031 in) 


Exhaust 


0.025 ~ 0.052 mm 


(0.001 ~ 0.002 in) 


<Limit>: 0.1 mm (0.0039 in) 



4-23 



VALVES AND VALVE SPRINGS 



ENG 



M 




2. Replace: 
•valve guide 

NOTE: 



To ease valve guide removal and installation, 
and to maintain the correct fit, heat the cylinder 
head to 100°C (21 2° F) in an oven. 



Remove the valve guide with a valve guide 

remover©. 

Install the new valve guide with the valve 

guide installer (2) and valve guide remover 

©. 

After installing the valve guide, bore the 

valve guide with a valve guide reamer (3) to 

obtain the proper valve-stem-to-valve-guide 

clearance. 



NOTE: 

After replacing the valve guide, reface the valve 
seat . 



fc& 


Valve guide remover 


Jr 


(4.0 mm, 0.16 in) 




90890-04111 


Valve guide installer 


(4.0 mm, 0.16 in) 


90890-04112 


Valve guide reamer 


(4.0 mm, 0.16 in) 


90890-04113 



3. Eliminate: 
•carbon deposits 

(from the valve face and valve seat) 

4. Check: 
•valve face 

Pitting/wear -+ Grind the valve face, 
•valve stem end 
Mushroom shape or diameter larger than the 
body of the valve stem -► Replace the valve. 



4-24 



VALVES AND VALVE SPRINGS 



ENG 






[ 


V 




& 






to- 




U 






i i 


//////////////////// m72m 



5. Measure: 
•valve margin thickness® 
Out of specification -► Replace the valve. 




Valve margin thickness 
0.6 mm ~ 0.8 mm 
(0.0236 ~ 0.0315 in) 
<LIMIT>: 0.5 mm (0.02 in) 



6. Measure: 
•valve stem runout 
Out of specification -► Replace the valve. 

NOTE: 

•When installing a new valve, always replace 
the valve guide. 

• If the valve is removed or replaced, always re- 
place the oil seal. 




Valve stem runout 
0.04 mm (0.0016 in) 




CHECKING THE VALVE SEATS 

The following procedure applies to all of the 
valves and valve seats. 

1. Eliminate: 
•carbon deposits 

(from the valve face and valve seat) 

2. Check: 

• valve seat 
Pitting/wear -+ Replace the cylinder head. 

3. Measure: 

•valve seat width® 

Out of specification -► Replace the cylinder 
head. 




Valve seat width 

Intake: 0.9 ~ 1.1 mm 

(0.0354 ~ 0.0433 in) 
<Limit>: 1.6 mm (0.06 in) 



4-25 



VALVES AND VALVE SPRINGS 





-J 


i) jj 










~ IIMIilli 



ENG 



V 



a. Apply Mechanic's blueing dye (Dykem) (b) 
onto the valve face. 

b. Install the valve into the cylinder head. 

c. Press the valve through the valve guide and 
onto the valve seat to make a clear impres- 
sion. 

d. Measure the valve seat width. 



NOTE: 

Where the valve seat and valve face contacted 
one another, the blueing will have been re- 
moved. 




£ 

6 


^ 




■. Lap: 

• valve face 

• valve seat 



NOTE: 

After replacing the cylinder head or replacing 
the valve and valve guide, the valve seat and 
valve face should be lapped. 



a. Apply a coarse lapping compound @ to the 
valve face. 

CAUTION: 



Do not let the lapping compound enter the 
gap between the valve stem and the valve 
guide. 

b. Apply molybdenum disulfide oil onto the 
valve stem. 

c. Install the valve into the cylinder head. 

d. Turn the valve until the valve face and valve 
seat are evenly polished, then clean off all of 
the lapping compound. 

NOTE: 

For the best lapping results, lightly tap the valve 
seat while rotating the valve back and forth be- 
tween your hand. 



4-26 



VALVES AND VALVE SPRINGS 



ENG 



m 



fl 

I V 


- f^y 




■ -~ III7lfil)l 




e. Apply a fine lapping compound to the valve 
face and repeat the above steps. 

f. After every lapping procedure, be sure to 
clean off all of the lapping compound from 
the valve face and valve seat. 

g. Apply Mechanic's blueing dye (Dykem) (6) 
onto the valve face. 

h. Install the valve into the cylinder head. 

i. Press the valve through the valve guide and 
onto the valve seat to make a clear impres- 
sion. 

j. Measure the valve seat width © again. If the 
valve seat width is out of specification, reface 
and lap the valve seat. 



rA—L 




I 


m '- 



CHECKING THE VALVE SPRINGS 

The following procedure applies to all of the 
valve springs. 
1. Measure: 
•valve spring free length ® 

Out of specification — ► Replace the valve 

spring. 




Valve spring free length 
Intake valve spring (inner) 

37.0 mm (1.46 in) 

<Limit>: 35mm (1.38 in) 
Intake valve spring (outer) 

38.4 mm (1.51 in) 

<l_imit>: 36.5mm (1.44 in) 
Exhaust valve spring 

41.7 mm (1.64 in) 

<Limit>: 39.5mm (1.56 in) 



4-27 



VALVES AND VALVE SPRINGS 



ENG 



M 






v___y 


1] 171171)1 




2. Measure: 
•compressed spring force® 
Out of specification — ► Replace the valve 
spring. 

(6) Installed length 




Compressed spring force 
(installed) 

Intake valve spring inner 
69 ~ 79 N (15.51 ~ 17.76 1b, 
7.04 ~ 8.06 kg) at 30.0 mm 
(1.18 in) 

Intake valve spring outer 
114 ~ 132 N (25.63 ~ 29.67 lb, 
11.62 ~ 13.46 kg) at 32.5 mm 
(1.28 in) 

Exhaust valve spring 
160 ~ 184 N (35.97 ~ 41.36 lb, 
16.32 ~ 18.76 kg) at 36.1 mm 
(1.42 in) 



3. Measure: 
•valve spring tilt® 
Out of specification 
spring. 



Replace the valve 




Max. Spring tilt 

Intake valve spring inner 

2.5°/1.6mm(0.06in) 
Intake valve spring outer 

2.5°/1.7mm(0.07in) 
Exhaust valve spring 

2.5°/1.8mm(0.07in) 



CHECKING THE VALVE LIFTERS 

The following procedure applies to all of the 

valve lifters. 

1. Check: 
•valve lifter 
Damage/scratches -+ Replace the valve lift- 
ers and cylinder head. 

EAS00247 

INSTALLING THE VALVES 

The following procedure applies to all of the 
valves and related components. 

1. Deburr: 
•valve stem end 

(with an oil stone) 

2. Lubricate: 

• valve stem © 
•oil seal© 
(with the recommended lubricant) 



Recommended lubricant 
Molybdenum disulfide oil 



4-28 



VALVES AND VALVE SPRINGS 



ENG 



M 




3. Install: 
•lower spring^seati 
•oil seald 
•valve® 
•valve spring inner (intake only) i 
•valve spring outer (2) 
• upper spring seat © 
(into the cylinder head) 

NOTE: 



•Make sure that each valve is installed in its 
original place. Refer to the following em- 
bossed marks. 

• Install the valve spring with the larger pitch ® 
facing up. 



Smaller pitch 




4. Install: 
•valve cotters© 

NOTE: 



Install the valve cotters by compressing the 
valve spring with the valve spring compressor 
(2) and attachment (3). 




Valve spring compressor 
90890-04019, YM-04019 

Attachment 

90890-04114, YM-01 253-1 



5. To secure the valve cotters © onto the valve 
stem, lightly tap the valve tip with a soft-face 
hammer. 

CAUTION: 



Hitting the valve tip with excessive force 
could damage the valve. 



4-29 



VALVES AND VALVE SPRINGS 



ENG 



1b 



6. Lubricate: 
• valve pad 
(with the recommended lubricant) 



Recommended lubricant 
Molybdenum disulfide oil 



7. Install: 
• valve pad 
•valve lifter 



NOTE: 

•The valve lifter must move smoothly when ro- 
tated with a finger. 

•Each valve lifter and valve pad must be rein- 
stalled in its original position. 



4-30 



PICKUP COIL AND PICKUP COIL ROTOR 



PICKUP COIL AND PICKUP COIL ROTOR 



ENG 



10Nm(1.0tTTkg, 7.2ft«lb) 



15Nm(1.5m»kg, 11 ft»lb) 



12Nm(1.2m»kg, 8.7ft»lb) 



Order 



Job/ Part 



Removing the pickup coil and 
pickup coil rotor 

Riders seat and fuel tank 

Bottom cowling and right side 

cowling 

Engine oil 



Generator cover 



Q'ty 



Remarks 



% 




Remove the parts in the order listed. 

Refer to "SEATS" and "FUEL TANK" in 

chapter 3. 

Refer to "COWLINGS" in chapter 3. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 

Refer to "STARTER CLUTCH AND 

GENERATOR". 



4-31 



PICKUP COIL AND PICKUP COIL ROTOR 



ENG 



m 



10Nm(1.0m»kg, 7.2 ft«lb) 

i 



15Nm(1.5m»kg, 11 ft»lb) 




35 Nm (3.5 m»kg, 25 ft'lb) 



12Nm(1.2nvkg, 8.7ft»lb) 



Order 


Job/ Part 


Q'ty 


Remarks 


1 


Clutch cable 






2 


Clutch cable holder 






3 


Pickup coil coupler 




Disconnect 


4 


Pickup coil cover 






5 


Pickup coil cover gasket 






6 


Dowel pin 
Pickup coil 


2 


Refer to "REMOVING/INSTALLING 


7 




THE PICKUP COIL ROTOR". 


8 


Pickup rotor 




For installation reverse the removal 
procedure. 



4-32 



PICKUP COIL AND PICKUP ROTOR 



ENG 



M 




REMOVING THE PICKUP COIL ROTOR 

1. Remove: 
•clutch cable holder© 
•pickup coil cover (2) 

NOTE: 

Loosen each bolt 1 /4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 



2. Remove: 

• pickup coil rotor bolt © 
•plain washer© 

• pickup coil rotor © 

NOTE: 

While holding the generator rotor© with the ro- 
tor holding tool ©, loosen the pickup coil rotor 
bolt. 



P 



Sheave holder 

90890-01701, YS-01 880 



INSTALLING THE PICKUP COIL ROTOR 

1. Install: 
•pickup coil rotor© 
•plain washer 
• pickup coil rotor bolt 

NOTE: 

When installing the pickup coil rotor, align the 
pin © in the crankshaft sprocket with the 
groove @ in the pickup coil rotor. 



4-33 



PICKUP COIL AND PICKUP ROTOR 



ENG 



m 




2. Tighten: 
• pickup coil rotor bolt © 



35 Nm (3.5 nrkg, 25 fHb) 



NOTE: 

While holding the generator rotor (2) with the 
sheave holder®, tighten the pickup coil rotor 
bolt. 




Sheave holder 

90890-01701, YS-01 880 



3. Apply: 
•sealant 
(onto the pickup coil lead grommet) 




Yamaha bond No.1215 

90890-85505, ACC-1 100-1 5-01 



4. Install: 
•pickup Coil cover 
•clutch cable holder 



NOTE: 

•When installing the pickup coil cover, align the 
timing chain guide (intake side) pin © of the 
with the hole (2) in the pickup coil cover. 

•Tighten the pickup coil cover bolts in stages 
and in a crisscross pattern. 



4-34 



STARTER CLUTCH AND GENERATOR 



ENG 



tQ 



STARTER CLUTCH AND GENERATOR 




65 Nm (6.5 m»kg, 47 ft'lb) 



10Nm(1.0m»kg, 7.2 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the starter clutch and gener- 




Remove the parts in the order listed. 




ator 








Riders seat and fuel tank 




Refer to "SEATS" and "FUEL TANK" in 
chapter 3. 




Buttom and left side cowlings 




Refer to "COWLINGS" in chapter 3. 




Engine oil 




Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 




Coolant treserver 




Drain. 

Refer to "CHANGING THE COOLANT" in 

chapter 3. 


1 


Stator coil assembly coupler 




Disconnect. 


2 


Generator cover 




Refer to "REMOVING/INSTALLING 
THE GENERATOR". 


3 


Generator rotor cover gasket 






4 


Dowel pin 


2 




5 


Stator coil assembly lead holder 






6 


Stator coil assembly 







4-35 



STARTER CLUTCH AND GENERATOR 



ENG 



% 



XI 65 Nm (6.5 m«kg, 47 fHb) 



10Nm(1.0nvkg, 7.2 ft-lb) 




Order 


Job/Part 


Q'ty 


Remarks 


7 
8 
9 


Generator rotor bolt 
Plain washer 
Generator rotor 




" Refer to "REMOVING/INSTALLING 
_ THE GENERATOR". 


10 


Starter one-way assy 






11 


Idler gear shaft 






12 


Idler hear 






13 


Starter clutch gear 




For installation reverse the removal 
proceduer. 



4-36 



STARTER CLUTCH AND GENERATOR 




ENG 



V 



REMOVING THE GENERATOR 

1. Remove: 
• generator rotor cover ® 

NOTE: 



Loosen each bolt 1 1 A of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 



2. Remove: 
• generator rotor bolt (T) 
•Plain washer 

NOTE: 



While holding the generator rotor (2) with the 
sheave holder (3), loosen the generator rotor 
bolt. 

Do not allow the sheave holder to touch the pro- 
jection on the generator rotor. 




Sheave holder 

90890-01701, YS-01 880 



3. Remove: 
• generator rotor ® 
(with the flywheel puller ( 



and adapter (3. 




Flywheel puller 

90890-01362, YU-33270 
Flywheel puller attachment 

90890-04089, YM-33282 



4-37 



STARTER CLUTCH AND GENERATOR 




ENG 



m 



REMOVING THE STARTER CLUTCH 

1. Remove: 

• Generator 

• Starter one-way assy © 

• Idler gear shaft (2) 

• Idler gear (3) 

• Starter clutch gear (4) 




CHECKING THE STARTER CLUTCH 

1. Check: 

• Starter one-way assy 
Damage/wear ->- Replace. 

2. Check: 
•Idler gear 

• Idler gear shaft 
•starter clutch gear 

Pitting/Burrs/chips/roughness/wear -»- Re- 
place the defective parts. 

3. Check: 

Starter clutch operation 

a. Install the starter clutch gear (T) onto the 
starter clutch (2) and hold the starter clutch. 

b. When turning the starter clutch drive gear 
clockwise [A] , the starter clutch and the start- 
er clutch gear should engage. 

If the starter clutch gear and starter clutch do 
not engage, the starter clutch is faulty and 
must be replaced. 

c. When turning the starter clutch drive gear 
counterclockwise E] , it should turn freely. If 
the starter clutch drive gear does not turn 
freely, the starter clutch is faulty and must be 
replaced. 



4-38 



STARTER CLUTCH AND GENERATOR 



ENG 



% 




■—yen 


J^JfT 


>c_ 


(D J^ 

© 






4v^ 

Cp 




EAS00355 

INSTALLING THE STARTER CLUTCH 

1. Install: 
•starter clutch gear© 

• idler gear (2) 

• idler gear shaft (3) 

• startor one-way assy @ 

EAS00354 

INSTALLING THE GENERATOR 

1. Install: 
•generator rotor© 
•washer® 
•generator rotor bolt (3) 

NOTE: 

Clean the tapered portion of the crankshaft and 
the generator rotor hub with lacquer tinner. 

2. Tighten: 
•generator rotor bolt (3) 

Xl 65 Nm (6.5 m»kg, 47 ft«lb) 



NOTE: 

While holding the generator rotor (2) with the 
sheave holder (3), tighten the generator rotor 
bolt. 

Do not allow the sheave holder to touch the pro- 
jection on the generator rotor. 



P 



Sheave holder 

90890-01701, YS-01 880 



3. Apply: 
•sealant 
(onto the stator coil assembly lead grommet) 




Yamaha bond No.1215 

90890-85505, ACC-1 100-1 5-01 



4. Install: 

• stator coil 

5. Install: 
•generator rotor cover 

NOTE: 



Tighten the generator rotor cover bolts in stages 
and in a crisscross pattern. 



4-39 



SHIFT SHAFT 



SHIFT SHAFT 



ENG 



V 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the shift shaft 




Remove the parts in the order listed. 




Coolant reserver 




Drain. 

Refer to "CHANGING THE COOLANT" in 

chapter 3. 




Drive sprocket cover, sift rod and sift 




Refer to "ENGINE". 




arm. 






1 


Shift shaft cover 


1 




2 


Shift shaft cover gasket 


1 




3 


Dowel pin 


2 




4 


Oil seal 


1 




5 


Sift shaft 


1 


Refer to "INSTALLING THE SHIFT 
SHAFT". 



4-40 



SHIFT SHAFT 



ENG 



M 




Order 


Job/ Part 


Q'ty 


Remarks 


6 


Shift shaft spring 






7 


Collar 






8 


Stopper lever spring 






9 


Circrip 






10 


Washer 






11 


Stopper lever 






12 


Collar 




Refer to "INSTALLING THE SHIFT 


13 


Washer 




SHAFT". 


14 


Shift shaft spring stopper 




For installation reverse the removal 
procedure. 



4-41 



SHIFT SHAFT 



ENG 


WB 




EAS00329 

CHECKING THE SHIFT SHAFT 

1. Check: 
• shift shaft© 

Bends/damage/wear -+ Replace, 
•shift shaft spring© 

Damage/wear — ► Replace. 



CHECKING THE STOPPER LEVER 

1. Check: 
• stopper lever© 
Bends/damage -+ Replace. 
Roller turns roughly -+ Replace the stopper 
lever. 



INSTALLING THE SHIFT SHAFT i 

1. Install: Ju\ 

• shift shaft spring stopper © m*A 



22 Nm (2.2 m«kg, 16ft»lb) 



• stopper lever spring 

• washer 

• stopper lever® 

NOTE: 



• Apply LOCTITE® to the threads of the shift 
shaft spring stopper. 

• Hook the ends of the stopper lever spring onto 
the stopper lever and the crankcase boss. 

• Mesh the stopper lever with the shift drum seg- 
ment assembly. 




2. Install: 

• shift shaft© 

• collor 

NOTE: 



• Lubricate the oil seal lips with lithium soap 

base grease. 
> Install the end of the shift shaft spring onto the 

shift shaft spring stopper© 



4-42 



CLUTCH 



ENG 



%1 



CLUTCH 

CLUTCH COVER 




12Nm(1.2nvkg, 8.7 fHb) 



l2Nm(1.2nvkg, 8.7 ft-lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the clutch cover 

Bottom cowing and right side cowling 
Engine oil 




Remove the parts in the order listed. 

Refer to "COWLINGS" in chapter 3. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 




Coolant 




in chapter 3. 

Drain. 

Refer to "CHANGING THE COOLANT" in 


1 
2 


Therm bypass hose 
Clutch cable 


1 
1 


chapter 3. 



4-43 



CLUTCH 



ENG 



V 




12Nm(1.2m«kg, 8.7 fMb) 



Nm(1.2m«kg, 8.7 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 


3 

4 
5 


Clutch cover 

Clutch cover gasket 
Dowel pin 


1 

1 
2 


Refer to "REMOVING/INSTALLING 
THE CLUTCH". 

For installation reverse the removal 
procedure. 



4-44 



CLUTCH 



ENG 



m 




Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the clutch cover 




Disassemble the parts in the order listed. 




assembly 






© 


Circlip 


2 




© 


Plain washer 


2 




® 


Pull lever 


1 


Refer to "INSTALLING THE CLUTCH". 


® 


Pull lever spring 


1 




(5) 


Oil seal 


1 




© 


Bearing 


2 


For assembly, reverse the disassembly 
procedure. 



4-45 



CLUTCH 



CLUTCH 



ENG 



^, 



m 



XI 70 Nm (7.0 nvkg, 51 ft«lb) 




8 Nm (0.8 m»kg, 5.8 ft»lb) 



Order 



Job/Part 



Q'ty 



Remarks 



Removing the clutch 

1 Compression spling 

2 Pressure plate 

3 Pull rod 

4 Bearing 

5 Friction plate 

6 Clutch plate 

7 Clutch plate 

8 Clutch boss nut 

9 Look washer 

10 Clutch boss 



6 
1 
1 
1 
8 
7 
1 
1 
1 
1 



Remove the parts in the order listed. 



~] Refer to "INSTALLING THE CLUTCH". 



Refer to"REMOVING/INSTALLING 
THE CLUTCH". 



4-46 



CLUTCH 



ENG 


WB 



70 Nm (7.0 m«kg, 51 fHb) 




CD 



XI 8 Nr " (0-8 nrkg, 5.8 ft'lb) 



Order 



Job/Part 



11 



Thrust plate 



Q'ty 



Remarks 



For installation, reverse the removal 
procedure. 



4-47 



CLUTCH 



ENG 



m 




REMOVING THE CLUTCH 

1. Remove: 
•clutch cover© 

NOTE: 



Loosen each bolt 1 1 A of a turn at a time, in 

stages and in a crisscross pattern. 

After all of the bolts are fully loosened, remove 

them. 

• Pressure plate 

• Fricttion and clutch plates 

2. Straighten the lock washer tab. 

3. Loosen: 
•clutch boss nut© 

NOTE: 

While holding the clutch boss (2) with the clutch 
holding tool (3), loosen the clutch boss nut. 



P 



Clutch holding tool 

90890-04086, YM-91042 



4. Remove: 
•clutch boss nut© 
• lock washer (2) 
•clutch boss® 
•thrust plate© 



CHECKING THE FRICTION PLATES 

The following procedure applies to all of the fric- 
tion plates. 

1. Check: 
•friction plate 

Damage/wear -+ Replace the friction plates 
as a set. 

2. Measure: 

•friction plate thickness 
Out of specification — ► Replace the friction 
plates as a set. 

NOTE: 

Measure the friction plate at four places. 




Friction plate thickness 

2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 
<Limit>: 2.8 mm (0.11 in) 



4-48 



CLUTCH 



ENG 



% 




EAS00281 

CHECKING THE CLUTCH PLATES 

The following procedure applies to all of the 
clutch plates. 

1. Check: 
•clutch plate 

Damage -+ Replace the clutch plates as a 
set. 

2. Measure: 

•clutch plate warpage 
(with a surface plate and thickness gauge 
®) 

Out of specification -► Replace the clutch 
plates as a set. 




Max. clutch plate warpage 
0.1 mm (0.0039 in) 





CHECKING THE CLUTCH SPRINGS 

The following procedure applies to all of the 
clutch springs. 

1. Check: 
clutch spring 

Damage -+ Replace the clutch springs as a 
set. 

2. Measure: 

clutch spring free length (a) 

Out of specification -► Replace the clutch 

springs as a set. 

Clutch spring free length 




Clutch spring free length 
55 mm (2.17 in) 
<Limit>: 54 mm (2.13 in) 



EAS00284 

CHECKING THE CLUTCH HOUSING 

1. Check: 
•clutch housing dogs 
Damage/pitting/wear -+ Deburr the clutch 
housing dogs or replace the clutch housing. 

NOTE: . 

Pitting on the clutch housing dogs will cause er- 
ratic clutch operation. 



2. Check: 
•bearing 
Damage/wear 
ing. 



Replace the clutch hous- 



4-49 



CLUTCH 




ENG 



M 



EAS00285 

CHECKING THE CLUTCH BOSS 

1. Check: 
• clutch boss splines 
Damage/pitting/wear -+ Replace the clutch 
boss. 



NOTE: 

Pitting on the clutch boss splines will cause er- 
ratic clutch operation. 



CHECKING THE PRESSURE PLATE 

1. Check: 
•pressure plate® 

Cracks/damage -+ Replace. 
• bearing (2) 

Damage/wear -► Replace. 



CHECKING THE PULL LEVER SHAFT AND 
PULL ROD 

1. Check: 

•pull lever shaft pinion gear teeth ® 
• pull rod teeth (6) 

Damage/wear -+ Replace the pull rod and 

pull lever shaft as a set. 

2. Check: 

•pull rod bearing 
Damage/wear -+ Replace. 



4-50 







CLUTCH 



ENG 



% 



EAS00296 

INSTALLING THE CLUTCH 

1. Install: 

• thrust plate © 
•clutch boss© 

2. Install: 

• lock washer ® ISlSffl 
•clutch boss nut (4) 



70 Nm (7.0 nvkg, 51 ft»lb) 



NOTE: 

While holding the clutch boss© with the clutch 
holding tool (5), tighten the clutch boss nut. 




Clutch holding tool 

90890-04086, YM-91042 



3. Bend the lock washer tab along a flat side of 
the nut. 

4. Lubricate: 

• friction plates 
•clutch plates 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



5. Install: 
•friction plates 
•clutch plates 

NOTE: 



First, install a friction plate and then alternate 
between a clutch plate and a friction plate. 



6. Install: 
•washer 
•bearing© 
•pull rod© 



NOTE: 

Install the pull rod so that the teeth a face to- 
wards the rear of the motorcycle. Then, install 
the clutch cover. 

Tighten the clutch cover bolts in stages and in a 
crisscross pattern. 
Apply oil onto the bearing. 
Apply molybdenum disulfide grease onto the 
pull rod. 



4-51 




CLUTCH 



ENG 



m 



7. Install: 
• pressure plate © 
•clutch springs 
•clutch spring bolts 



8 Nm (0.8 tirkg, 5.8 ft»lb) 



NOTE: 

Tighten the clutch spring bolts in stages and in a 
criss cross pattern. 

Align the punch mark © in the pressure plate 
with the punch mark (a) in the clutch boss. 



8. Install: 
•clutch cover 



12Nm(1.2m«kg, 8.7 ft«lb) 



NOTE: 

• When installing the clutch cover, push the pull 
lever and check that the punch mark (a) on the 
pull lever aligns with the mark® on the clutch 
cover. Make sure that the pull rod teeth and 
pull lever shaft pinion gear are engaged. 

• Tighten the clutch cover bolts in stages and in 
a crisscross pattern. 



4-52 



OIL PAN AND OIL PUMP 



ENG 



m 



OIL PAN AND OIL PUMP 




10 Nm (1.0 nrkg, 
7.2 ft-lb) 



Order 


Job/ Part 


Q'ty 


Remarks 




Removing the oil pan and oil pump 




Remove the parts in the order listed. 




Engine oil 




Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 




Coolant 




Drain. 

Refer to "CHANGING THE COOLANT" in 

chapter 3. 




Radiator assembly and water pump 




Refer to "RADIATOR" and "WATER 




assembly 




PUMP" in chapter 5. 




Exhaust pipe assembly 




Refer to "ENGINE". 


1 


Oil level switch couplar 


1 


Disconnect. 


2 


Oil level switch 


1 





4-53 



OIL PAN AND OIL PUMP 



ENG 



m 




10 Nm (1.0 nvkg, 
7.2 ft'lb) 



Order 


Job/Part 


Q'ty 


Remarks 


3 


Oil level switch lead holder 






4 


Oil pan 




Refer to "REMOVEING/INSTALLING 


5 


Oil pan gasket 




THE OIL PAN. 


6 


Dowel pin 


2 - 




7 


Oil strainer 




Refer to "INSTALLING THE OIL 
STRAINER". 


8 


Oil pipe 






9 


Oil delivery pipe 






10 


Gear cover 






11 


Dowel pin 


2 


Refer to "INSTALLING THE OIL PUMP". 


12 


Oil pump assembly 






13 


Relief valve assembly 




For installation, reverse the removal 
procedure. 



4-54 



OIL PAN AND OIL PUMP 



ENG 



% 



OIL PUMP 




Order 


Job/Part 


Q'ty 


Remarks 




Disassemblying the oil pump 




Disassemble the parts in the order listed. 




assembly 






© 


Oil pump rotor housing 


1 




© 


Dowel pin 


2 




(3) 


Oil pump inner rotor 






@ 


Oil pump outer rotor 






® 


Dowel pin 






© 


Washer 






® 


Oil pump cover 






® 


Driver gear 




For assembly reverse the disassembly 
procedure. 



4-55 



OIL PAN AND OIL PUMP 



ENG 



% 




REMOVING THE OIL PAN 

1. Remove: 
•oil level switch© 
•oil pan(2) 
•oil pan gasket 
• dowel pins 

NOTE: 



Loosen each bolt 1/4 of a turn at a time, in 

stages and in a crisscross pattern. 

After all of the bolts are fully loosened, remove 

them. 




CHECKING THE OIL PUMP 

1. Check: 

• oil/pump driven gear© 

• rotor housing (2) 
Cracks/damage/wear 
tive part(-s). 



Replace the defec- 



2. Measure: 
• inner-rotor-to-outer-rotor-tip clearance (§) 
•outer-rotor-to-oil-pump-cover clearance (b) 
Out of specification — ► Replace the oil pump. 

© Inner rotor 

(2) Outer rotor 

(3) Oil pump cover 



7R 


Inner-rotor-to-outer-rotor-tip 


:±\ 


clearance 




0.03 ~ 0.09 mm 


(0.0012 ~ 0.0035 in) 


<Limit>: 0.15 mm (0.0059 in) 


Outer-rotor-to-oil-pump-cover 


clearance 


0.03 ~ 0.08 mm 


(0.0012 ~ 0.0031 in) 


<Limit>: 0.15 mm (0.0059 in) 



4-56 



OIL PAN AND OIL PUMP 



ENG 


%m 




3. Check: 
•oil pump operation 
Unsmooth — ► Repair or replace the defective 
part(-s). 



CHECKING THE RELIEF VALVE 

1. Check: 

• relief valve body © 

• relief valve (2) 

• spring (3) 
•O-ring® 

Damage/wear 
part(-s). 



Replace the defective 



CHECKING THE OIL DELIVERY PIPE AND 
OIL PIPE 

1. Check: 

•oil delivery pipe© 

•oil pipe© 
Damage -t- Replace. 

Obstruction — ► Wash and blow out with com- 
pressed air. 



CHECKING THE OIL STRAINER 

1. Check: 
•oil strainer© 
Damage -+ Replace. 
Contaminants -+ Clean with engine oil. 



CHECKING THE OIL NOZZLES 

The following procedure applies to all of the oil 
nozzles. 
1. Check: 
•oil nozzle© 
•0-ring(D 
Damage/wear -► Replace the oil nozzle, 
oil nozzle passage 
Obstruction — ► Blow out with compressed air. 



4-57 



OIL PAN AND OIL PUMP 




ENG 



m 



ASSEMBLING THE OIL PUMP 

1. Lubricate: 

• inner rotor 

• outer rotor 
•impeller shaft 

(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



2. Check: 
•oil pump operation 
Refer to "CHECKING THE OIL PUMP". 

EAS00376 

INSTALLING THE OIL PUMP 

1. Install: 
•oil pump© 



12Nm(1.2m«kg, 8.7ft»lb) 



NOTE: 

Install the oil pump assembly drive chain onto 
the oil pump assembly driven sprocket. 




INSTALLING THE OIL STRAINER 

1. Install: 
•oil strainer© 

NOTE: 

The arrow (a) on the oil strainer housing must 
point towards the front of the engine. 



(TV 










\ 




Uv vi 


Jo p-' J( Tt^fp^Jj ^s 






—"*% 



INSTALLING THE OIL PAN 

1. Install: 

•dowel pins 

•oil pan gasket 
•oil pan© 



«oil level switch© 




12Nm(1.2m«kg, 8.7 fMb) 



■engine oil drain bolt ( 



X1 1 Nm (1 .0 m«kg, 7.2 fMb) 



43 Nm (4.3 nvkg, 31 ft«lb) 



NOTE: 

•Tighten the oil pan bolts in stages and in a 

crisscross pattern. 
• Lubricate the oil level switch O-ring with lithium 

soap base grease. 



4-58 



CRANKCASE 



CRANKCASE 



ENG 



V 




Order 


Job/Part 


Q'ty 


Remarks 




Separating the crankcase 




Remove the parts in the order listed. 




Engine 




Refer to "ENGINE". 




Cylinder head 




Refer to "CYLINDER HEAD". 




Starter clutch and generator 




Refer to "STARTER CLUTCH AND 
GENERATOR". 




Shift shaft 




Refer to "SHIFT SHAFT". 




Pickup coil and pickup rotor 




Refer to "PICKUP COIL AND PICKUP 
ROTOR". 




Clutch assembly 




Refer to "CLUTCH". 




Water pump assembly 




Refer to "WATER PUMP" in chapter 5. 




Oil pan and oil pump 




Refer to "OIL PAN AND OIL PUMP". 



4-59 



CRANKCASE 





Order 


Job/Part 


Q'ty 


Remarks 


1 


Timing chain 


1 




2 


Oil pump drive chain guide 


1 




3 


Oil pump drive chain 


1 




4 


Lower crankcase 


1 


Refer to "DISASSEMBLY/ASSEMBLY 
THE CRANKCASE". 


5 


Dowel pin 


3 


For installation, reverse the removal 
procedure. 



4-60 



CRANKCASE 



ENG 






OIL BAFFLE PLATES AND OIL FILTER BOLT 




— — . _ ■ 


Order 


Job/Part 


Q'ty 


Remarks 




Removing the oil baffle plates and 
oil filter bolt 




Remove the parts in the order listed. 


1 
2 
3 
4 
5 


Transmission 
Oil baffle plate 
Oil baffle plate 
Oil delivery pipe 
Bearing 
Lower crankcase 




Refer to "TRANSMISSION". 


6 


Oil filter bolt 






7 


Upper crankcase 




For instalation, reverse the removal 
procedure. 



4-61 



CRANKCASE 




ENG 



m 



DISASSEMBLING THE CRANKCASE 

1 . Place the engine upside down. 

NOTE: 

•Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern. After all of 
the bolts are fully loosened, remove them. 

•Loosen the bolts in decreasing numerical or- 
der (refer to the numbers in the illustration). 

•The numbers embossed on the crankcase in- 
dicate the crankcase tightening sequence. 

2. Remove: 
crankcase bolts 

3. Remove: 

• lower crankcase 

CAUTION: 



Tap on one side of the crankcase with a soft- 
face hammer. Tap only on reinforced por- 
tions of the crankcase, not on the crankcase 
mating surfaces. Work slowly and carefully 
and make sure that the crankcase halves 
separate evenly. 

M8 x 85 mm bolts: (T) ~ (7) © 

M8 x 115 mm bolts: (8) (9) 

M8 x 65 mm bolt: © © 

M6 x 65 mm bolts: © © © @ 

M6 x 55 mm bolts: © @ ~ @ 

M6 x 45 mm bolt: © © ~ @ 

M6 x 75 mm bolt: © 

4. Remove: 
• dowel pins 



4-62 



CRANKCASE 



ENG 



% 



CHECKING THE CRANKCASE 

1 . Thoroughly wash the crankcase halves in a 
mild solvent. 

2. Thoroughly clean all the gasket surfaces and 
crankcase mating surfaces. 

3. Check: 
•upper crankcase 
•lower crankcase 

Cracks/damage -k Replace, 
•oil delivery passages 
Obstruction — ► Blow out with compressed air. 




CHECKING THE BEARINGS AND OIL 
SEALS 

1. Check: 
•bearings 

Clean and lubricate the bearings, then rotate 
the inner race with your finger. 
Rough movement — ► Replace. 

2. Check: 
oil seals 
Damage/wear — ► Replace. 

CHECKING THE SPROCKETS AND CHAINS 

1. Check: 
•crankshaft sprocket® 
•oil/water pump assembly drive sprocket (2) 
Cracks/damage/wear -+ Replace the de- 
fective part(-s). 



2. Check: 

•timing chain® 
Damage/stiffness -> Replace the timing 
chain and crankshaft sprocket as a set. 

•oil/water pump assembly drive chain (2) 
Damage/stiffness -► Replace the oil/water 
pump assembly drive chain and oil/water 
pump assembly drive sprocket as a set. 



4-63 



CRANKCASE 




ASSEMBLING THE CRANKCASE 

1. Lubricate: 
•crankshaft journal bearings 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



/tr u 'oV_ 


Lnfl=ft=0D3J<*sS 


L. — |o/-j\_ 


- JO] 

- [o I 

r° 




o 

m 




\5 


J ^ I ) r~> 



HIS3S 




2. Apply: 
•sealant 
(onto the crankcase mating surfaces and the 
groove ® of the oil baffle plate) 



P 



Yamaha bond No. 1215 

90890-85505, ACC-1 100-1 5-01 



NOTE: 

Do not allow any sealant to come into contact 
with the oil gallery or crankshaft journal bear- 
ings. Do not apply sealant to within 2 ~ 3 mm of 
the crankshaft journal bearings. 

3. Install: 
• dowel pin 



4. Set the shift drum assembly and transmis- 
sion gears in the neutral position. 




5. Install: 
•lower crankcase© 
(onto the upper crankcase (2 

CAUTION: 



Before tightening the crankcase bolts, make 
sure that the transmission gears shift cor- 
rectly when the shift drum assembly is 
turned by hand. 



4-64 




CRANKCASE 



ENG 



4L 



« 



6. Install: 
•crankcase bolts 



NOTE: 

•Lubricate the bolt threads with engine oil. 

• Install a washer on bolts © ~ ©. 

• Install a gasket on bolt @. 

• Not lubricate seal botts © © 

•Tighten the bolts in the tightening sequence 
cast on the crankcase. 



M8 x 85 mm bolts: © ~ (7) ® 
M8 x 115 mm bolts: (8) (9) 
M8 x 65 mm bolt: © © 
M6 x 65 mm bolts: © ® © @ 
M6 x 55 mm bolts: @ © ~ @ 
M6 x 45 mm bolts: @ © ~ @ 
M6 x 75 mm bolts: (l3) 





Bolt©~@ 

12Nm(1.2rrrkg, 8.7 fMb) 




Bolt © ~ © 

14Nm(1.4m.kg, 10fHb) 
Bolt © ~ © 

24 Nm (2.4 nrkg, 17 ft-lb) 



A WARNING 



Always use new copper washers. 



4-65 



CONNECTING RODS AND PISTONS 



ENG 



m 



CONNECTING RODS AND PISTONS 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the connecting rods and 
pistons 

Lower crankcase 




Remove the parts in the order listed. 

Separate. 

Refer to "CRANKCASE". 


1 
2 
3 
4 
5 


Connecting rod cap 
Big end lower bearing 
Big end upper bearing 
Piston pin clip 
Piston pin 


4 - 

4 

4 

8 

4 


Refer to "REMOVING/INSTALLING THE 
CONNECTING RODS AND PISTONS". 


6 


Piston 


4 




7 


Connecting rod 


4 - 





4-66 



CONNECTING RODS AND PISTONS 



ENG 



% 




Order 


Job/Part 


Q'ty 


Remarks 


8 
9 
10 


Top ring 
2nd ring 
Oil ring 


4 - 
4 
4 - 


" Refer to "REMOVING/INSTALLING THE 
. CONNECTING RODS AND PISTONS". 

For installation, reverse the removal 
procedure. 



4-67 



CONNECTING RODS AND PISTONS 




ENG 



m 



EAS00393 

REMOVING THE CONNECTING RODS AND 
PISTONS 

The following procedure applies to all of the 
connecting rods and pistons. 
1. Remove: 

•connecting rod cap® 

•big end bearings 

NOTE: 

Identify the position of each big end bearing so 
that it can be reinstalled in its original place. 









CD 




kJi 


1% 




®^ 


w 


W 






2. Remove: 
•piston pin clips® 
•piston pin (2) 
•piston® 
• connecting rod 

CAUTION: 



Do not use a hammer to drive the piston pin 
out. 



NOTE: 

•For reference during installation, put identifi- 
cation marks on the piston crown. 

• Before removing the piston pin, deburrthe pis- 
ton pin clip groove and the piston pin bore area 
in the piston. If both areas are deburred and 
the piston pin is still difficult to remove, remove 
it with the piston pin puller®. 



P 



Piston pin puller 

90890-01304, YU-01 304 



3. Remove: 
•top ring 
•2nd ring 
•oil ring 

NOTE: 



To remove a piston ring, open the end gap with 
your fingers and lift the other side of the ring 
over the piston crown. 



4-68 



CONNECTING RODS AND PISTONS 



ENG 



% 











® 


11210101 



EAS00262 

CHECKING THE CYLINDER AND PISTONS 

The following procedure applies to all of the cyl- 
inders and pistons. 

1. Check: 

• piston wall 

•cylinder wall 

Vertical scratches -+ Replace the crank- 
cases, and the piston and piston rings as a 
set. 

2. Measure: 
•piston-to-cylinder clearance 

a. Measure cylinder bore "C" with the cylinder 
bore gauge. 

NOTE: 

Measure cylinder bore "C" by taking side-to- 
side and front-to-back measurements of the 
cylinder. Then, find the average of the measure- 
ments. 




Cylinder bore gauge 

90890-03017, YU-03017 



Cylinder bore "C" 


65.50 ~ 65.51 mm 
(25.787 ~ 25.791 in) 


Max. taper "T" 


0.05 mm (0.002 in) 


Out of round "R" 


0.05 mm (0.002 in) 




b. If out of specification, replace the crank- 
cases, and the piston and piston rings as a 
set. 

c. Measure piston skirt diameter "P" with the 
micrometer. 




Micrometer 

90890-03008, YU-03008 



(a) 4 mm from the bottom edge of the piston 





Piston size "P" 


Standard 


65.460 ~ 65.475 mm 
(2.5772 ~ 2.5778 in) 



d. If out of specification, replace the piston and 
piston rings as a set. 



4-69 



CONNECTING RODS AND PISTONS 



ENG 



V 



e. Calculate the piston-to-cylinder clearance 
with the following formula. 



Piston-to-cylinder clearance = 
Cylinder bore "C" - 
Piston skirt diameter "P" 




Piston-to-cylinder clearance 
0.025 ~ 0.050 mm 
(0.001 ~ 0.002 in) 
<Limit>: 0.07 mm (0.0028 in) 



f. If out of specification, replace the crank- 
cases, and the pistons and piston rings as a 
set. 




CHECKING THE PISTON RINGS 

1. Measure: 
•piston ring side clearance 
Out of specification — ► Replace the piston 
and piston rings as a set. 

NOTE: 

Before measuring the piston ring side clear- 
ance, eliminate any carbon deposits from the 
piston ring grooves and piston rings. 




7R 


Piston ring side clearance 


±\ 


Top ring 




0.030 ~ 0.065 mm 


(0.0012 ~ 0.0026 in) 


<Limit>: 0.115 mm (0.005 in) 


2nd ring 


0.020 ~ 0.055 mm 


(0.0008 ~ 0.0022 in) 


<l_imit>: 0.115 mm (0.005 in) 



2. Install: 
• piston ring 
(into the cylinder) 

NOTE: 



Level the piston ring in the cylinder with the pis- 
ton crown. 



(a) 5 mm (0.20 in) 



4-70 



CONNECTING RODS AND PISTONS 




3. Measure: 
• piston ring end gap 
Out of specification - 
NOTE: 



Replace the piston ring. 



The oil ring expander spacer's end gap cannot 
be measured. If the oil ring rail's gap is exces- 
sive, replace all three piston rings. 




Piston ring end gap 
Top ring 

0.15 ~ 0.25 mm 

(0.006 ~ 0.009 in) 

<Limit>: 0.50 mm (0.02 in) 
2nd ring 

0.40 ~ 0.50 mm 

(0.016 ~ 0.02 in) 

<Limit>: 0.85 mm (0.033 in) 
Oil ring 

0.10 ~ 0.35 mm 

(0.004 ~ 0.014 in) 



CHECKING THE PISTON PINS 

The following procedure applies to all of the pis- 
ton pins. 
1. Check: 
•piston pin 
Blue discoloration/grooves -»■ Replace the 
piston pin and then check the lubrication sys- 
tem. 




2. Measure: 
• piston pin outside diameter® 
Out of specification -+ Replace the piston 
pin. 



Piston pin outside diameter 
15.991 ~ 16.000 mm 
(0.6296 ~ 0.6299 in) 






Ib^l/ 




Vu 








r\ I— I Tr ' i l!P*^y \ 




'© ^| 



3. Measure: 
• piston pin bore diameter (in the piston) 
Out of specification -+• Replace the piston 
pin. 




Piston pin bore diameter 

(in the piston) 

16.002 ~ 16.013 mm 
(0.6300 ~ 0.6304 in) 



4-71 



CONNECTING RODS AND PISTONS 



ENG 



% 



4. Calculate: 
• piston-pin-to-piston-pin-bore clearance 
Out of specification -► Replace the piston 
pin. 



Piston-pin-to-piston-pin-bore clearance = 
Piston pin bore diameter (in the piston) 

Piston pin outside diameter 




Piston-pin-to-piston-pin-bore 
clearance 

0.002 ~ 0.022 mm 

(0.00008 ~ 0.0009 in) 

<l_imit>: 0.072 mm (0.0028 in) 



CHECKING THE BIG END BEARINGS 

1. Measure: 
• crankshaft-pin-to-big-end-bearing clearance 
Out of specification -+ Replace the big end 
bearings. 




Crankshaft-pin-to-big-end- 
bearing clearance 
0.028 ~ 0.052 mm 
(0.0011 ~ 0.002 in) 



© ® 










I / ~~~~ ] 


=:i 


- 


^Vv 


] / 












II(i::ii;iii 



The following procedure applies to all of the 
connecting rods. 



CAUTION: 



Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clearance 
and prevent engine damage, the big end 
bearings must be installed in their original 
positions. 

a. Clean the big end bearings, crankshaft pins, 
and bearing portions of the connecting rods. 

b. Install the big end upper bearing into the con- 
necting rod and the big end lower bearing 
into the connecting rod cap. 

NOTE: 

Align the projections® on the big end bearings 
with the notches © in the connecting rod and 
connecting rod cap. 



4-72 



CONNECTING RODS AND PISTONS 



ENG 



%1 




c. Put a piece of Plastigauge® © on the crank- 
shaft pin. 

d. Assemble the connecting rod halves. 
NOTE: 

• Do not move the connecting rod or crankshaft 
until the clearance measurement has been 
completed. 

• Lubricate the bolt threads and nut seats with 
molybdenum disulfide grease. 

• Make sure that the "Y" mark© on the connect- 
ing rod faces towards the left side of the crank- 
shaft. 

• Make sure that the characters (d) on both the 
connecting rod and connecting rod cap are 
aligned. 



e. Tighten the connecting rod nuts. 
CAUTION: 



•When tightening the connecting rod nuts, 
be sure to use an F-type torque wrench. 

•After tightening the connecting rod nut to 
the specified torque, turn the connecting 
rod nut another+90°. 

Refer to "INSTALLING THE PISTONS AND 
CONNECTING RODS". 






Connecting rod nut 

15 Nm (1.5 nrkg, 11 fMb) + 90 c 




f. Remove the connecting rod and big end 
bearings. 

Refer to "REMOVING THE CONNECTING 
RODS AND PISTONS". 

g. Measure the compressed Plastigauge® 
width © on the crankshaft pin. 

If the crankshaft-pin-to-big-end-bearing 
clearance is out of specification, select re- 
placement big end bearings. 



4-73 



CONNECTING RODS AND PISTONS 



ENG 



m 




2. Select: 
•big end bearings ("Pi" 

NOTE: 



"P 4 ") 



• The numbers stamped into the crankshaft web 
and the numbers on the connecting rods are 
used to determine the replacement big end 
bearing sizes. 

• "Pi" ~ "P4" refer to the bearings shown in the 
crankshaft illustration. 



For example, if the connecting rod "Pi" and 
the crankshaft web "Pi" numbers are "5" and 
"1" respectively, then the bearing size for 
"Pi" is: 



"Pi" (connecting rod) - "P-|" (crank- 
shaft) = 
5-1 =4 



BIG END BEARING COLOR CODE 


1 


blue 


2 


black 


3 


brown 


4 


green 



INSTALLING THE PISTONS AND CONNECT- 
ING RODS 

The following procedure applies to all of the pis- 
tons and cylinders. 
1. Install: 

•top ring 

•2nd ring 

• oil ring 

NOTE: 

Be sure to install the piston rings so that the 
manufacturer's marks or numbers face up. 



4-74 



CONNECTING RODS AND PISTONS 



ENG 



In 




2. Install: 
•piston© 

(onto the respective connecting rod (2)) 
•piston pin (3) 
•piston pi clip® Ifljffl 

NOTE: . 

•Apply engine oil onto the piston pin. 

• Make sure that the "Y" mark® on the connect- 
ing rod faces left when the arrow mark © on 
the piston is pointing up. Refer to the illustra- 
tion. 

• Reinstall each piston into its original cylinder 
(numbering order starting from the left: #1 to 
#4). 




3. Offset: 
• piston ring end gaps 

@ Top ring 

(6) Lower oil ring rail 

© Upper oil ring rail 

(3) 2nd ring 

[A] Intake side 



4. Lubricate: 
•piston 
•piston rings 
•cylinder 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 



5. Lubricate: 
•bolt threads 
•nut seats 
(with the recommended lubricant) 



Recommended lubricant 

Molybdenum disulfide grease 



4-75 



CONNECTING RODS AND PISTONS 



ENG 



V 



i. Lubricate: 
•crankshaft pins 
•big end bearings 

•connecting rod big end inner surface 
(with the recommended lubricant) 



Recommended lubricant 
Engine oil 




7. Install: 

•big end bearings 
•connecting rod assembly 

(into the cylinder and onto the crankshaft 

pin). 

• connecting rod cap 
(onto the connecting rod) 

NOTE: 

•Align the projections on the big end bearings 
with the notches in the connecting rods and 
connecting rod caps. 

• Be sure to reinstall each big end bearing in its 
original place. 

•While compressing the piston rings with one 
hand, install the connecting rod assembly into 
the cylinder with the other hand. 

• Make sure that the "Y" marks (a) on the con- 
necting rods face towards the left side of the 
crankshaft. 

• Make sure that the characters (6) on both the 
connecting rod and connecting rod cap are 
aligned. 

8. Align: 

• bolt heads 

(with the connecting rod caps) 

9. Tighten: 
•connecting rod nuts 



15 Nm (1.5 nvkg, 11 ft«!b)+90' 



a. Replace the connecting rod bolts and nuts 
with new ones. 



CAUTION: 



Tighten the connecting rod bolts using the 
plastic-region tightening angle method. 
Always install new bolts and nuts. 



4-76 



CONNECTING RODS AND PISTONS 



ENG 




%3 



b. Clean the connecting rod bolts and nuts. 

c. Tighten the connecting rod nuts. 

d. Put a mark® on the corner of the connecting 
rod nut (D and the connecting rod ®. 



e. Tighten the nut further to reach the specified 
angle (90°). 



A WARNING 



When the nut is tightened more than the 
specified angle, do not loosen the nut and 
then retighten it. 

Replace the bolt with a new one and perform 
the procedure again. 



CAUTION: 

• Do not use a torque wrench to tighten the 

nut to the specified angle. 
•Tighten the nut until it is at the specified 

angles. 



NOTE: 

When using a hexagonal nut, note that the 
angle from one corner to another is 60°. 



4-77 



CRANKSHAFT 




CRANKSHAFT 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the crankshaft 




Remove the parts in the order listed. 




Crankcase lower 




Separate. 

Refer to "CRANKCASE". 




Connecting rods and pistons 




Refer to "CONNECTING RODS AND 
PISTONS". 


1 
2 
3 


Crankshaft 

Crankshaft journal lower bearing 

Crankshaft journal upper bearing 


1 - 
5 
5 - 


" Refer to "REMOVING/INSTALLING 
. THE CRANKSHAFT". 

For installation, reverse the removal 
procedure. 



4-78 




9 o 


o 


^ 




T T 


T — 


liraiooc 



CRANKSHAFT 



ENG 



%0 



REMOVING THE CRANKSHAFT 

1. Remove: 
• crankshaft © 

•crankshaft journal upper bearings 
(from the upper / lower crankcase) 

NOTE: 



Identify the position of each crankshaft journal 
upper bearing so that it can be reinstalled in its 
original place. 



CHECKING THE CRANKSHAFT 

1. Measure: 
•crankshaft runout 

Out of specification -► Replace the crank- 
shaft. 




Max. crankshaft runout 
0.03 mm (0.0012 in) 



2. Check: 
•crankshaft journal surfaces 
•crankshaft pin surfaces 
•bearing surfaces 
Scratches/wear -► Replace the crankshaft. 



CHECKING THE CRANKSHAFT JOURNAL 
BEARINGS 

1. Measure: 
•crankshaft-journal-to-crankshaft-journal- 
bearing clearance 

Out of specification -+ Replace the crank- 
shaft journal bearings. 




Crankshaft-journal-to-crankshaft- 
journal-bearing clearance 

0.034 ~ 0.058 mm 

(0.0013 ~ 0.0023 in) 



CAUTION: 



Do not interchange the crankshaft journal 
bearings. To obtain the correct crankshaft- 
journal-to-crankshaft-journal-bearing 
clearance and prevent engine damage, the 
crankshaft journal bearings must be 
installed in their original positions. 



4-79 



CRANKSHAFT 




ENG 



m 



a. Clean the crankshaft journal bearings, 
crankshaft journals, and bearing portions of 
the crankcase. 

b. Place the upper crankcase upside down on a 
bench. 

c. Install the crankshaft journal upper bearings 
(?) and the crankshaft into the upper crank- 
case. 



NOTE: 

Align the projections ® on the crankshaft jour- 
nal upper bearings with the notches (5) in the 
upper crankcase. 



d. Put a piece of Plastigauge® 
crankshaft journal. 

NOTE: 



on each 



Do not put the Plastigauge® over the oil hole in 
the crankshaft journal. 

e. Install the crankshaft journal lower bearings 
into the lower crankcase and assemble the 
crankcase. 



NOTE: 

• Align the projections® on the crankshaft jour- 
nal lower bearings with the notches © in the 
lower crankcase. 

• Do not move the crankshaft until the clearance 
measurement has been completed. 

f. Tighten the bolts to specification in the tight- 
ening sequence cast on the crankcase. 



\ 


Bolt © ~ @ 

12Nm(1.2nvkg, 8.7 fMb) 




Bolt © <3> 

14Nm(1.4nrkg, 10 fMb) 
Bolt © ~ © 

24 Nm (2.4 m»kg, 17 fMb) 



NOTE: 

Lubricate the crankcase bolt threads with en- 
gine oil. 



4-80 



CRANKSHAFT 



ENG 




% 



g. Remove the lower crankcase and the crank- 
shaft journal lower bearings. 

h. Measure the compressed Plastigauge® 
width © each crankshaft journal. 
If the clearance is out of specification, select 
replacement crankshaft journal bearings. 



2. Select: 
•crankshaft journal bearings (J-| ~ J 5 ) 

NOTE: 

• The numbers stamped into the crankshaft web 
and the numbers stamped into the lower 
crankcase are used to determine the replace- 
ment crankshaft journal bearing sizes. 

•"Ji" ~ "J 5 " refer to the bearings shown in the 
crankshaft illustration. 

• If "J-|" ~ "J 5 " are the same, use the same size 
for all of the bearings. 



For example, if the crankcase "J-|" and crank- 
shaft web "J-i" numbers are "6" and "2" respec- 
tively, then the bearing size for "J-," is: 



Bearing size for J^ 
"J!" (crankcase) - "J," (crankshaft 
web) - 1 = 
6-2-1 =3 



CRANKSHAFT JOURNAL BEARING 
COLOR CODE 





White 


1 


Blue 


2 


Black 


3 


Brown 


4 


Green 



NOTE: 

If the size is the same for all "J-j to J 5 ", one digit 
for that size is indicated, (crankcase side only) 



4-81 



CRANKSHAFT 



ENG 



%1 




INSTALLING THE CRANKSHAFT 

1. Install: 
•crankshaft journal upper bearings 
(into the upper / lower crankcase) 

NOTE: 



• Align the projections® on the crankshaft jour- 
nal upper bearings with the notches (b) in the 
upper crankcase. 

• Be sure to install each crankshaft journal up- 
per bearing in its original place. 



4-82 



TRANSMISSION 



ENG 



M 



TRANSMISSION 



|12Nm(1.2nvkg, 8.7ft«lb) 




10Nm(1.0nvkg, 7.2ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the transmission 




Remove the parts in the order listed. 




Crankcase lower 




Separate. 

Refer to "CRANKCASE". 




Shift shaft and stopper lever 




Refer to "SHIFT SHAFT". 


1 


Drive axle assembly 






2 


Circlip 






3 


Oil seal 






4 


Bearing 






5 


Shift bar stopper 






6 


Shift fork guide bar 


2 





4-83 



TRANSMISSION 




|12Nm(1.2nvkg, 8.7 ft»lb) 




10Nm(1.0m'kg, 7.2 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 


7 

8 

9 

10 

11 

12 


Spring 

Shift fork "L" 

Shift fork "Ft" 

Shift drum assembly 

Shift fork "C" 

Main axle assembly 


4 - 


" Refer to "INSTALLING THE 

TRANSMISSION". 

Refer to "REMOVING THE 
_ TRANSMISSION". 

For installation, reverse the removal 
procedure. 



4-84 



TRANSMISSION 



ENG 



% 




Order 



(2) 



Job/Part 



do) 



Disassembling the main axle 
assembly 

Bearing 

2nd pinion gear 

Toothed lock washer 

Toothed lock washer retainer 

6th pinion gear 

Collar 

Washer 

Circlip 

3rd pinion gear 

Circlip 



Q'ty 



Remarks 



Remove the parts in the order listed. 



4-85 



TRANSMISSION 





Order 


Job/Part 


Q'ty 


Remarks 


<fi) 


Washer 






© 


5th pinion gear 






© 


Collar 






© 


Main axle 






© 


Bearing housing 






© 


Bearing 




For installation, reverse the removal 
procedure. 



4-86 



TRANSMISSION 



ENG 



m 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the drive axle 




Remove the parts in the order listed. 




assembly 






CD 


Washer 






<D 


1st wheel gear 






(3) 


Collar 






® 


5th wheel gear 






© 


Circlip 






© 


Washer 






® 


3rd wheel gear 






(8) 


Collar 






CD 


Toothed lock washer 






© 


Toothed lock washer retainer 






© 


4th wheel gear 







4-87 



TRANSMISSION 





Order 


Job/Part 


Q'ty 


Remarks 


© 


Collar 








© 


Washer 








® 


Circrip 








© 


6th wheel gear 








© 


Circrip 








ft 


washer 








© 


2nd wheel gear 








© 


Collar 








@) 


Collar 








@ 


Oil seal 
Bearing 








@> 


Circrip 








© 


Drive axle 




For installation, 
procedure. 


reverse the removal 



4-88 



TRANSMISSION 



ENG 






EAS00420 



REMOVING THE TRANSMISSION 

1. Remove: 

•drive axle assembly 

2. Remove: 

• main axle assembly © 
(with the Torx® wrench T30) 

a. Insert two bolts (2) of the proper size, as 
shown in the illustration, into the main axle 
assembly bearing housing. 

b. Tighten the bolts until they contact the crank- 
case surface. 

c. Continue tightening the bolts until the main 
axle assembly comes free from the upper 
crankcase. 



CHECKING THE SHIFT FORKS 

The following procedure applies to all of the shift 
forks. 
1. Check: 
•shift fork cam follower© 
•shift fork pawl (2) 
Bends/damage/scoring/wear -+ 
Replace the shift fork. 



2. Check: 
•shift fork guide bar 
Roll the shift fork guide bar on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent shift fork 
guide bar. 



4-89 












1 




r> 






ii^:::-:."::rrr: 


| 










» 
































110)71)2 









9 

1 1 


^XD 












— - — 


- 


- 




















., J 




A 












A 

IIO)7 


II 




TRANSMISSION 



ENG 


wB 



3. Check; 
•shift fork movement 
(along the shift fork guide bar) 
Rough movement — ► Replace the shift 
fork(-s) and shift fork guide bar as a set. 



CHECKING THE SHIFT DRUM ASSEMBLY 

1. Check: 

•shift drum grooves 
Damage/scratches/wear -+ Replace the 
shift drum assembly. 

• shift drum segment © 
Damage/wear ->- Replace the shift drum as- 
sembly. 

•shift drum bearing (2) 
Damage/pitting — ► Replace the shift drum 
assembly. 

EAS00425 

CHECKING THE TRANSMISSION 

1. Measure: 
•main axle runout 
(with a centering device and dial gauge (D) 
Out of specification -► Replace the main 
axle. 




Max. main axle runout 
0.02 mm (0.0008 in) 



2. Measure: 
•drive axle runout 
(with a centering device and dial gauge CD) 
Out of specification -+ Replace the drive 
axle. 




Max. drive axle runout 
0.02 mm (0.0008 in) 



3. Check: 

•transmission gears 
Blue discoloration/pitting/wear — 
Replace the defective gear(-s). 

•transmission gear dogs 
Cracks/damage/ rounded edges 
Replace the defective gear(-s). 



4-90 



TRANSMISSION 



ENG 



% 



4. Check: 

•transmission gear engagement 
(each pinion gear to its respective wheel 
gear) 

Incorrect -► Reassemble the transmission 
axle assemblies. 

5. Check: 

•transmission gear movement 
Rough movement — ► Replace the defective 
part(-s). 

6. Check: 
•circlips 

Bends/damage/looseness — ► Replace. 



INSTALLING THE TRANSMISSION 

1. Install: 
•main axle assembly 
•shift fork "C" 
•shift drum assembly 
•shift fork "R" 
• shift fork "L" 
•springs 

•shift fork guide bars 
•drive axle assembly 

NOTE: 



•Carefully position the shift forks so that they 
are installed correctly into the transmission 
gears. 

• Install shift fork "C" into the groove in the 3rd 
and 4th pinion gear on the main axle. 

• Install shift fork "L" into the groove in the 6th 
wheel gear and shift fork "R" into the groove in 
the 5th wheel gear on the drive axle. 

• Make sure that the drive axle bearing circlip is 
inserted into the grooves in the upper crank- 
case. 

2. Check: 
•transmission 
Rough movement -+ Repair. 

NOTE: 

Oil each gear, shaft, and bearing thoroughly. 



4-91 



COOL 


X 



CHAPTER 5. 
COOLING SYSTEM 

RADIATOR 5-1 

CHECKING THE RADIATOR 5-3 

INSTALLING THE RADIATOR 5-4 

OIL COOLER 5-5 

CHECKING THE OIL COOLER 5-7 

INSTALLING THE OIL COOLER 5-7 

THERMOSTAT 5-9 

CHECKING THE THERMOSTAT 5-11 

INSTALLING THE THERMOSTAT 5-11 

WATER PUMP 5-13 

DISASSEMBLING THE WATER PUMP 5-15 

CHECKING THE WATER PUMP 5-15 

ASSEMBLING THE WATER PUMP 5-16 



RADIATOR 



RADIATOR 



COOL 


X 



COOLING SYSTEM 




Order 


Job/Part 


Q'ty 


Remarks 




Removeing the radiator 




Remove the parts in the order listed. 




Rider seat and fuel tank 




Refer to "SEATS" and "FUEL TANK" in 
chapter 3. 




Air filter case and heat protector plate 




Refer to "AIRFILTER CASE AND IGNI- 
TION COILS" in chapter 3. 




Bottom cowling and side cowlings 




Refer to "COWLINGS" in chapter 3. 




Coolant 




Drain. 


1 


Coolant reserver hose 


1 




2 


Breather hose 


2 




3 


Radiator outlet hose 


1 


Disconnect. 



5-1 



RADIATOR 



COOL 


X 




Order 


Job/Part 


Q'ty 


Remarks 


4 


Radiator inlet hose 




Disconnect. 


5 


Oil cooler outlet hose 






6 


Thermo switch coupler 




Disconnect. 


7 


Radiator fan motor coupler 




Disconnect. 


8 


Radiator 






9 


Radiator fan 




For installation reverse the removal 
procedure. 



5-2 





RADIATOR 



COOL 


X 



EAS00455 

CHECKING THE RADIATOR 

1. Check: 
• radiator fins 
Obstruction -> Clean. 

Apply compressed air to the rear of the radia- 
tor. 
Damage — ► Repair or replace. 

NOTE: 

Straighten any flattened fins with a thin, flat- 
head screwdriver. 



2. Check: 
• radiator hoses 
Cracks/damage -+ Replace. 



3. Measure: 
• radiator cap opening pressure 
Below the specified pressure -► Replace the 
radiator cap. 




Radiator cap opening pressure 
110 ~ 140 kPa 
(1.1 ~ 1.4 kg/cm 2 , 
16.0 ~ 20.3 psi) 



a. Install the radiator cap tester© and adapter 
(2) onto the radiator cap (3). 




Radiator cap tester 

90890-01325, YU-24460-01 
Adapter 

90890-01352, YU-33984 



b. Apply the specified pressure for ten seconds 
and make sure that there is no drop in pres- 
sure. 

4. Check: 
• radiator fan 
Damage -v Replace. 
Malfunction -+ Check and repair. 
Refer to "COOLING SYSTEM" in chapter 8. 



5-3 



RADIATOR 



COOL 


X 



INSTALLING THE RADIATOR 

1. Fill: 

• cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

2. Check: 

• cooling system 

Leaks — ► Repair or replace any faulty part. 

3. Measure: 

• radiator cap opening pressure 

Below the specified pressure -+ Replace the 

radiator cap. 

Refer to "CHECKING THE RADIATOR". 



5-4 



OIL COOLER 



COOL 


X 



OIL COOLER 




Order 


Job/ Part 


Q'ty 


Remarks 


1 
2 
3 
4 


Removing the oil cooler 

Radiator assembly 
Exaust pipe assembly 
Engine oil 

Oil cooler outlet hose 

Bolt 

Washer 

Oil cooler 


1 

1 - 
1 
1 - 


Remove the parts in the order listed. 

Refer to "RADIATOR". 

Refer to "ENGINE" in chapter 4. 

Drain. 

Refer to "CHANGING THE ENGINE OIL" 

in chapter 3. 

" Refer to "INSTALLING THE OIL 
COOLER". 



5-5 



OIL COOLER 



cool y^ 




Order 


Job/ Part 


Q'ty 


Remarks 


5 


Oil cooler inlet hose 






6 


Water jacket joint 






7 


Water jacket joint hose 






8 


Water pump outlet pipe 






9 


Water pump outlet hose 






10 


Water pump inlet hose 




For installation, reverse the removal 
procedure. 



5-6 




OIL COOLER 



COOL 


X 



CHECKING THE OIL COOLER 

1. Check: 
•oil cooler 

Cracks/damage -+ Replace. 

2. Check: 

•oil cooler inlet hose 
•oil cooler outlet hose 
Cracks/damage/wear -+ Replace. 



3. Check: 
•water jacket joint 
•water jacket joint inlet hose 
•water pump outlet hose 
Cracks/damage -+ Replace. 



EBS00459 

INSTALLING THE OIL COOLER 

1. Clean: 
•mating surfaces of the oil cooler and the 
crankcase 
(with a cloth dampened with lacquer thinner) 




2. Install: ^^ 
• O-ring ES 
•oil cooler© 
•washer (2 
•bolt® 

NOTE: 



63 Nm (6.3 m»kg, 46 ft«lb) 



• Before installing the oil cooler, lubricate the oil 
cooler bolt and O-ring with a thin coat of engine 
oil. 

• Make sure that the O-ring is positioned proper- 
ly- 

• Align the projection® on the oil cooler with the 
slot® in the crankcase. 

3. Bend the lock washer tab along a flat side of 
the bolt. 



5-7 



OIL COOLER 



COOL y^ 



4. Fill: 
•cooling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

• crankcase 

(with the specified amount of the recom- 
mended engine oil) 

Refer to "CHANGING THE ENGINE OIL" in 
chapter 3. 

5. Check: 

• cooling system 

Leaks -+ Repair or replace any faulty part. 

6. Measure: 

• radiator cap opening pressure 

Below the specified pressure — ► Replace the 

radiator cap. 

Refer to "CHECKING THE RADIATOR". 



5-8 



THERMOSTAT 



THERMOSTAT 



COOL 


X 




Order 



Job/Part 



Removing the termostat 

Rider seat and fuel tank 

Coolant 



Air filter case 
Carburetor assembly 



Q'ty 



Remarks 



Remove the parts in the order listed. 

Refer to "SEAT" and "FUEL TANK" in 

chapter 3. 

Drain. 

Refer to "CHANGING THE COOLANT" in 

chapter 3. 

Refer to "AIRFILTER CASE AND 

IGNITION COILS" in chapter 3. 

Refer to "CARBURETORS" in chapter 6. 



5-9 



THERMOSTAT 



COOL 


X 




Order 



Job/Part 



Q'ty 



Remarks 



1 Radiator inlet hose 

2 Carburator outlet hose 

3 Thermostat cover 

4 Thermostat 



:] 



Refer to "INSTALLING THE 

THERMOSTAT 
For installation, revers the removal 
procedure. 



5-10 



THERMOSTAT 




-<D 




&& (b & & 




COOL 


X 



CHECKING THE THERMOSTAT 

1. Check: 
• thermostat© 
Does not open at 71 ~ 84°C(160 ~ 183°F) 
(without California) — ► Replace. 
Does not open at 82 ~ 95°C(178 ~ 203° F) 
(California) —► Replace. 

a. Suspend the thermostat in a container filled 
with water. 

b. Slowly heat the water. 

c. Place a thermometer in the water. 

d. While stirring the water, observe the thermo- 
stat and thermometer's indicated tempera- 
ture. 

© Thermostat 

(2) Thermometer 

(3) Water 

(4) Container 
[A] Fully closed 
\B\ Fully opens 



NOTE: 

if the accuracy of the thermostat is in doubt, re- 
place it. A faulty thermostat could cause serious 
overheating or overcooling. 

2. Check: 
•thermostat housing cover 
•thermostat housing 
Cracks/damage -► Replace. 

EB00467 

INSTALLING THE THERMOSTAT 

1. Install: 
•thermostat 

NOTE: 

Install the thermostat with its breather hole ® 
facing up. 

2. Install 

• thermostat cover 



10Nm(1.0m»kg,7.2ft'lb) 



NOTE: 

Befor installing the thermostat cover to the cyl- 
inder head, lubricate the O-ring with a thin coat 
of litium soap base grease. 



5-11 



THERMOSTAT 



COOL 


X 



3. Fill: 
•coolling system 

(with the specified amount of the recom- 
mended coolant) 

Refer to "CHANGING THE COOLANT" in 
chapter 3. 

4. Check: 
•cooling system 

Leaks -+ Repair or replace any faulty part. 

5. Measure: 

• radiator cap opening pressure 
Below the specified pressure -+- Replace the 
radiator cap. 
Refer to "CHECKING THE RADIATOR". 



5-12 



WATER PUMP 



cool y^ 



WATER PUMP 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the water pump assembly 




Remove the parts in the order listed. 




Coolant 




Drain. 

Refer to "CHANGING THE COOLANT" in 

chapter 3. 


1 


Water pump inlet hose 






2 


Water pump outlet hose 






3 


Water pump hose 






4 


Clutch wire and holder 






5 


Water pump 




For installation, reverse the removal 
procedure. 



5-13 



WATER PUMP 



COOL 


X 




Order 


Job/Part 


Q'ty 


Remarks 


© 

© 
® 

© 
© 


Disassembling the water pump 
assembly 

Water pump cover 

O-ring 

Impeller shaft (along with the impeller) 

Water pump seal 

Oil seal 

Bearing 

Circlip 




Disassemble the parts in the order listed. 

Refer to "DISASSEMBLING/ 
ASSEMBLING THE WATER PUMP". 

For assembly, reverse the disassembly 
procedure. 



5-14 



COOL 


X 




WATER PUMP 



DISASSEMBLING THE WATER PUMP 

1. Remove: 

•water pump seal© 

NOTE: 

Tap out the water pump seal from the inside of 
the water pump housing. 

(2) Water pump housing 

2. Remove: 
•oil seal© 
•circlip 

• bearing (2) 

NOTE: 

Tap out the bearing and oil seal from the outside 
of the water pump housing. 



(3) Water pump housing 

3. Remove: 
• rubber damper holder © 
•rubber damper© 

(from the impeller, with a thin, flat-head 

screwdriver) 

NOTE: 

Do not scratch the impeller shaft. 



CHECKING THE WATER PUMP 

1. Check: 
•water pump housing cover© 
•water pump housing (2) 
•impeller (3) 
•rubber damper© 
• rubber damper holder (5) 
Cracks/damage/wear -»• Replace. 



2. Check: 
•water pump seal 
•oil seal 

Cracks/damage/wear -+ Replace, 
•bearing 

Rough movement -+ Replace. 



5-15 



WATER PUMP 



COOL 


X 




ASSEMBLING THE WATER PUMP 

1. Install: 
•bearing 

oil seal © BUM 

(into the water pump housing (2)) 
NOTE: 



\® 


_ t^ — CS) 


(4) 









• Before installing the oil seal, apply tap water or 
coolant onto its outer surface. 

• Install the oil seal with a socket that matches 
its outside diameter. 



2. Install: 
•water pump seal© 

CAUTION: 



Never lubricate the water pump seal surface 
with oil or grease. 



NOTE: 

• Install the water pump seal with the special 
tools. 

• Before installing the water pump seal, apply 
Yamaha bond No. 121 5 (2) to the water pump 
housing®. 




Mechanical seal installer 
90890-04078, YM-33221 © 

Middle driven shaft bearing 

driver 

90890-04058, YM-04058-1 © 

Yamaha bond No. 1215 

90890-85505, ACC-1 100-1 5-01 



\A\ Push down. 




3. Install: ^^ 

• rubber damper © !£££ 

• rubber damper holder © 

NOTE: 



Before installing the rubber damper, apply tap 
water or coolant onto its outer surface. 



5-16 



WATER PUMP 



COOL 


X 





T 


f . 




J[o| 
H o j 

; jj [?) 


fjTv 



4. Measure: 
•impeller shaft tilt 
Out of specification 
(4). 

CAUTION: 



Repeat steps (3) and 



Make sure that the rubber damper and rub- 
ber damper holder are flush with the impel- 
ler. 




Max. impeller shaft tilt 
0.15 mm (0.006 in) 



(T) Straightedge 
(2) Impeller 



5-17 



CARB 


9 



CHAPTER 6. 
CARBURETORS 

CARBURETORS 6-1 

CHECKING THE CARBURETORS 6-7 

ASSEMBLING THE CARBURETORS 6-9 

INSTALLING THE CARBURETORS 6-11 

MEASURING AND ADJUSTING THE FUEL LEVEL 6-12 

CHECKING AND ADJUSTING THE THROTTLE POSITION 

SENSOR 6-13 

CHECKING THE FUEL PUMP 6-16 

CHECKING THE FUEL COCK 6-17 

CHECKING THE FUEL COCK OPERATION 6-17 

AIR INDUCTION SYSTEM 6-18 

AIR INJECTION 6-18 

AIR CUTOFF VALVE 6-18 

AIR INDUCTION SYSTEM DIAGRAMS 6-19 

CHECKING THE AIR INDUCTION SYSTEM 6-20 



CARBURETORS 



CARBURETORS 



CARB 


9 



CARBURETORS 




Order 



1 
2 
3 
4 



Job/Part 



Removing the carburetors 

Rider seat and fuel tank 

Air filter case and heat protector plate 

Starter cable 

Fuel hose 

Throttle position sensor coupler 

Throttle stop screw 



Q'ty 



Remarks 



Remove the parts in the order listed. 
Refer to "Seats" and "FUEL TANK" in 
chapter 3. 

Refer to "AIR FILTER CASE AND 
IGNITION COILS" in chapter 3. 



Disconnect 



6-1 



CARBURETORS 



CARB 


7 




Order 


Job/Part 


Q'ty 


Remarks 


5 
6 

7 


Therm bypass hose 
Carburetor joint clamp screw 
Throttle cable 


2 
4 
2 




8 
9 


Carburetor assembly 
Carburetor joint 


1 
4 




10 


Side cover 


2 


For installation, reverse the removal 
procedure. 



6-2 



CARBURETORS 



CARB 


9 




Order 



Job/Part 



1 
2 
3 
4 
5 

6 

7 

8 

9 

10 

11 



Separating the carburetors 

Starter plunger link 
Connecting bolt 
Connecting bolt 
Hose joint 
Spring 

Fuel feed pipe 

Fuel feed pipe 

Pipe 

Throttle stop screw 

Throttle position sensor 

Water pipe 



Q'ty 



1 
1 
1 
2 
2 

2 
1 
2 
1 
1 
2 



Remarks 



Remove the parts in the order listed. 

Refer to "ASSEMBLING THE 
CARBURETORS" 



Refer to "ASSEMBLING THE 
CARBURETORS" 



6-3 



CARBURETORS 



CARB 


9 




Order 



Job/Part 



12 Balance pipe 

13 Balance pipe bracket 

14 Throttle cable bracket 

1 5 Carburetor 



Q'ty 



2 
1 
1 
4 



Remarks 



For installation, reverse the removal 
procedure 



6-4 



CARBURETORS 



CARB 


7 




Order 


Job/ Part 


Q'ty 


Remarks 




Disassembling the carburetor 




Disassemble the parts in the order listed. 
N n TF- 


The following procedure applies to all of 


® 


Starter plunger 




the carburetors. 




© 


Air funnel 






® 


Vacuum chamber cover 






@ 


Piston valve spring 






(5) 


Jet needle holder 






© 


Jet needle kit 









Piston valve 




Refer to "ASSEMBLING THE 
CARBURETORS." 


(§) 


Fuel drain bolt 






® 


Float chamber 






© 


Float pivot pin 







6-5 



CARBURETORS 



CARB 


7 




Order 


Job/Part 


Q'ty 


Remarks 


(ft 


Float 






© 


Needle valve 






© 


Main jet 






® 


Main jet holder 






© 


Pilot jet 




For assembly, reverse the disassembly 
procedure. 



6-6 



CARBURETORS 



CARB 


7 



EAS00486 

CHECKING THE CARBURETORS 

The following procedure applies to all of the car- 
buretors. 
1. Check: 

•carburetor body 

•float chamber 
Cracks/damage -► Replace. 




2. Check: 
•fuel passages 
Obstruction -+ Clean. 



Wash the carburetor in a petroleum-based 
solvent. Do not use any caustic carburetor 
cleaning solution. 

Blow out all of the passages and jets with 
compressed air. 



3. Check: 

•float chamber body 
Dirt -+ Clean. 

4. Check: 

•float chamber rubber gasket © 
Cracks/damage/wear -► Replace. 





Rr 


—— ii 1 


fa 




5. Check: 
•float 
Damage 



Replace. 



Check: 

> needle valve © 

Damage/obstruction/wear -► Replace the 
needle valve, needle valve seat and O-ring 
as a set. 



6-7 



CARBURETORS 



CARB 


9 




7. Check: 
• piston valve © 

Damage/scratches/wear— ► Replace, 
•piston valve diaphragm ® 

Cracks/tears — ► Replace. 



8. Check: 
•vacuum chamber cover© 
• piston valve spring ® 
•jet needle holder® 
Cracks/damage — ► Replace. 



9. Check: 
•jet needle kit© 
•main jet (2) 
•main jet holder® 
• pilot jet (4) 
•starter plunger® 

Bends/damage/wear — ► Replace. 

Obstruction -+ Clean. 

Blow out the jets with compressed air. 



10. Check: 
•piston valve movement 
Insert the piston valve into the carburetor 
body and move it up and down. 
Tightness — ► Replace the piston valve. 



11. Check: 
•fuel feed pipes© 
•pipes® 
• hose joint ® 

Cracks/damage -► Replace. 

Obstruction — ► Clean. 

Blow out the pipes with compressed air. 



6-8 



CARBURETORS 



CARB 


9 



12. Check: 
•fuel hoses 

Cracks/damage/wear -► Replace. 
Obstruction -+ Clean. 
Blow out the hoses with compressed air. 




EAS00490 

ASSEMBLING THE CARBURETORS 

The following procedure applies to all of the car- 
buretors. 

CAUTION: 



•Before assembling the carburetors, wash 
all of the parts in a petroleumbased sol- 
vent. 

• Always use a new gasket. 

1. Install: 

• piston valve © 
•jet needle 

•jet needle holder 

• piston valve spring 
•vacuum chamber cover 



NOTE: 

• Install the end of the piston valve spring onto 
the spring guide on the vacuum chamber cov- 
er. 

• Align the tab @ on the piston valve diaphragm 
with the recess (B) in the carburetor body. 



6-9 



CARBURETORS 



CARB 


9 




2. Install: 
•pipes 

•fuel feed pipes 
•vacuum chamber pipe 
•vacuum chamber air vent hose 
•springs 
•float chamber air vent hoses 

• hose joint 

• spacers 
•copper washer 
•connecting bolts 

NOTE: 



• Do not tighten the connecting bolts yet. 

• Install the throttle valve lever® onto carbure- 
tors #2, #3, and #4 between the spring (2) and 
synchronizing screw®. 



3. Install: 
•starter plunger link® 

NOTE: 



Install the starter plunger link® onto each start- 
er plunger. 



4. Tighten: 
• connecting bolts 



7 Nm (0.7 nvkg, 5.1 ft'lb) 





~^p jcF^r 


33 


^yL 


oJIl^^ 




® © 


^ 



NOTE: 

• Place the carburetor assembly on a surface 
plate with the intake manifold side down. 
Then, tighten the connecting bolts while push- 
ing down the carburetor assembly with an 
even force. 

•After tightening the connecting bolts, check 
that the throttle valve lever and starter plunger 
link operate smoothly. 

5. Install: 
• starter cable ® 

NOTE: 



Install the starter cable holder ( 
er cable. 



onto the start- 



6-10 



CARBURETORS 



CARB 


9 



EAS00493 

INSTALLING THE CARBURETORS 

1. Adjust: 
•carburetor synchronization 
Refer to "SYNCHRONIZING THE CARBU- 
RETORS" in chapter 3. 



2. Adjust: 
•engine idling speed 



C\ 



Engine idling speed 
1250 ~ 1350r/min 



Refer to "ADJUSTING THE ENGINE ID- 
LING SPEED" in chapter 3. 



3. Adjust: 
•throttle cable free play 




Throttle cable free play (at the 
flange of the throttle grip) 
6 ~ 8 mm (0.24 ~ 0.31 in) 



Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 



6-11 



CARBURETORS 





© 




ff^f^^^^: 


Si. 


/® ! 


® 

1 






d) 










© 




CARB 


? 



MEASURING AND ADJUSTING THE FUEL 
LEVEL 

1. Measure: 
•fuel level® 
Out of specification -+ Adjust. 




Fuel level (below the mark on 
the body) 

17.5 ~ 18.5 mm (0.69 ~ 0.73 in) 



a. Stand the motorcycle on a level surface. 

b. Place the motorcycle on a suitable stand to 
ensure that the motorcycle is standing 
straight up. 

c. Install the fuel level gauge © onto the fuel 
drain pipe®. 




Fuel level gauge 

90890-01312, YM-01312-A 



d. Loosen the fuel drain bolt®. 

e. Hold the fuel level gauge vertically next to the 
line (4) on the float chamber. 

f. Measure the fuel level (§). 

NOTE: 

Fuel level readings should be equal on both 
sides of the carburetor assembly. 



2. Adjust: 
•fuel level 

a. Remove the carburetor assembly. 

b. Check the needle valve seat and needle 
valve. 

c. If either is worn, replace them as a set. 

d. If both are fine, adjust the float level by slight- 
ly bending the float tang ©. 

e. Install the carburetor assembly. 

f. Measure the fuel level again. 

g. Repeat steps (a) to (f) until the fuel level is 
within specification. 



6-12 



CARBURETORS 



CARB 


9 




EAS00502 

CHECKING AND ADJUSTING THE THROTTLE 
POSITION SENSOR 

NOTE: - 

Before adjusting the throttle position sensor, the 
engine idling speed should be properly ad- 
justed. 

1. Check: 
•throttle position sensor 
(installed on the carburetor) 

a. Disconnect the throttle position sensor cou- 
pler. 

b. Connect the pocket tester (Q x 1k) to the 
throttle position sensor. 



Tester positive probe - 
Tester negative probe 



blue© 
► black/blue i 



c. Measure the throttle position sensor maxi- 
mum resistance. 

Out of specification -+ Replace the throttle 
position sensor. 



m 



Throttle position sensor maximum 
resistance 

4.0 ~ 6.0 kQ at 20°C (68°F) 

(blue - black/blue) 



d. Connect the pocket tester (Q x Ik) to the 
throttle position sensor. 



Tester positive probe 
Tester negative probe 



yellow (3) 
► black/blue < 



e. While slowly opening the throttle, check that 
the throttle position sensor resistance is 
within the specified range. 

NOTE: . 

Check mainly that the resistance changes grad- 
ually when turning the throttle, since the read- 
ings (from closed to wide-open throttle) may dif- 
fer slightly from those specified. 



Out of specification or the resistance changes 
abruptly -► Go to step (2). 



m 



Throttle position sensor resistance 
~ 5 ± 1.0 kQ at 20°C (68°F) 
(yellow - black/blue) 



6-13 



CARBURETORS 



CARB 


9 



2. Check: 
•throttle position sensor 
(removed from the carburetor) 

a. Disconnect the throttle position sensor cou- 
pler. 

b. Remove the throttle position sensor from the 
carburetor. 

c. Connect the pocket tester (Q x 1k) to the 
throttle position sensor. 




Tester positive probe -► blue © 
Tester negative probe — ► black/blue (2) 



Measure the throttle position sensor maxi- 
mum resistance. 

Out of specification — ► Replace the throttle 
position sensor. 



at 



Throttle position sensor maxi- 
mum resistance 

4.0 ~ 6.0 kQ at 20°C (68°F) 

(blue - black/blue) 



e. Connect the pocket tester (Q. x 1k) to the 
throttle position sensor coupler. 



Tester positive probe - 
Tester negative probe 



yellow® 
► black/blue i 



f. While slowly opening the throttle, check that 
the throttle position sensor resistance is 
within the specified range. 

The resistance does not change or it changes 

abruptly -+ Replace the throttle position sensor. 

The slot is worn or broken — t- Replace the 

throttle position sensor. 

NOTE: 

Check mainly that the resistance changes grad- 
ually when turning the throttle, since the read- 
ings (from closed to wide-open throttle) may dif- 
fer slightly from those specified. 



m 



Throttle position sensor resistance 
~ 5±1.0kQat20°C(68°F) 
(yellow - black/blue) 



6-14 





f i .1 11 \:a. 








fl^Pt^ 






<<&K 














^wfoxLJ [ 




k 




3?^tO 1j^ 




^tF^ 


S3) 






® 




CARB 


9 



CARBURETORS 



3. Adjust: 
•throttle position sensor angle 

a. Set the main switch to "ON". 

b. Disconnect the throttle position sensor cou- 
pler. 

c. Reconnect the throttle position sensor cou- 
pler. 

NOTE: 

After reconnecting the throttle position sensor 
coupler, the tachometer switches to the throttle 
position sensor adjustment mode. 

d. Loosen the throttle position sensor screws 

(D. 

e. Adjust the throttle position sensor angle ac- 
cording to the following table. 

NOTE: ___ 

The angle of the throttle position sensor is indi- 
cated by the r/min which are displayed on the 
tachometer. 



Tachometer 
Reading 


Throttle posi- 
tion sensor 
angle 


Adjustment 
direction 


5000 rpm (2) 


Correct 


- 


rpm 


Incorrect 


® 


10000 rpm 


Incorrect 


® 



f. After adjusting the throttle position sensor 
angle, tighten the throttle position sensor 
screws. 



NOTE: 

To exit the throttle position sensor adjustment 
mode, start the engine or set the main switch to 
"OFF". 



6-15 




CARBURETORS 



CARB 


9 



CHECKING THE FUEL PUMP 

1. Check: 
•fuel pump® 

a. Remove the fuel tank. 

Refer to "FUEL TANK" in chapter 3. 

b. Disconnect the fuel-pump-to-carburetor fuel 
hose (2) from the carburetor. 

c. Connect the fuel-tank-to-fuel-pump fuel 
hose to the fuel tank and then set the fuel 
cock to "ON". 

d. Place a container under the end of the fuel 
hose®. 

e. Start the engine and check if fuel flows from 
the fuel hose®. 



Fuel flows. 


Fuel pump is OK. 


Fuel does not 
flow. 


Replace the fuel 
pump. 



f. Stop the engine and check if the fuel stops 
flowing from the fuel hose (2). 



Fuel stops flowing. 


Fuel pump is OK. 


Fuel flows. 


Replace the fuel 
pump. 



6-16 





CARBURETORS 



CARB 


7 




CHECKING THE FUEL COCK 

1. Remove 
•fuel tank 
•fuel filter® 
•fuel cock© 

2. Check: 
•fuel cock 

Cracks/damage/wear -* Replace. 

3. Check: 

•fuel cock strainer© 
(with compressed air) 
Dirt/obstruction -> Clean. 
Damage -v Replace. 

4. Install 
•fuel cock 
•fuel filter 
•fuel tank 



CHECKING THE FUEL COCK OPERATION 

NOTE: — 

After installing the fuel cock, check its opera- 
tion. 

1 . Check that the fuel cock lever is turned to 
"ON" or "OFF". 

2. Place a container under the end of the fuel 
hose. 

3. Check: 

•fuel cock operation 
a. Suck on the end of the vacuum hose. 
Fuel flows. 
Fuel cock is OK. 
Fuel does not flow. 
Replace the fuel cock. 



6-17 



AIR INDUCTION SYSTEM 



CARB 


9 



AIR INDUCTION SYSTEM 

AIR INJECTION 

The air induction system burns unburned ex- 
haust gases by injecting fresh air (secondary 
air) into the exhaust port, reducing the emission 
of hydrocarbons. 

When there is negative pressure at the exhaust 
port, the reed valve opens, allowing secondary 
air to flow into the exhaust port. The required 
temperature for burning the unburned exhaust 
gases is approximately 600 to 700°C (1112 to 
1292°F). 




d 



VIEW 1. (NO FLOW) 




I 



<= 



El 



IB 
VIEW 2.(FLOW) 



AIR CUTOFF VALVE 

The air cutoff valve is operated by the intake gas 
pressure through the piston valve diaphragm. 
Normally, the air cutoff valve is open to allow 
fresh air to flow into the exhaust port. During 
sudden deceleration (the throttle valve sudden- 
ly closes), negative pressure is generated and 
the air cutoff valve is closed in order to prevent 
after-burning. 

Additionally, at high engine speeds and when 
the pressure decreases, the air cutoff valve au- 
tomatically closes to guard against a loss of per- 
formance due to self-EGR. 
(This "low-boost close" function is the same as 
on the FZR600 (3HW).) 

VIEW1. (NO FLOW) 

When decelerating (the throttle closes), the 

valve will close. 

VIEW 2. (FLOW) 

During normal operation the valve is open. 

[A] From the air filter 

\B\ To the reed valve 

\C\ To the carburetor joint 



6-18 



AIR INDUCTION SYSTEM 



CARB 


9 



AIR INDUCTION SYSTEM DIAGRAMS 




(T) Reed valve 

(2) Air cleaner 

(3) Air cutoff valve 

Carburetor joint (cylinder #3) 



\A\ To the cylinders 

\B\ To the air cutoff valve 

\C\ To cylinder #1 

\D\ To cylinder #2 

\M To cylinder #3 

00 To cylinder #4 



6-19 



AIR INDUCTION SYSTEM 



CARB 


9 



CHECKING THE AIR INDUCTION SYSTEM 

1. Check: 

• hoses 

Loose connection -+ Connect properly. 
Cracks /damage -t- Replace. 

• pipes 
Cracks/damage -k Replace. 




2. Check: 
• air cutoff valve 
Cracks/damage -+ Replace. 



6-20 



CHAS(3^) 



CHAPTER 7. 
CHASSIS 

FRONT WHEEL AND BRAKE DISCS 7-1 

REMOVING THE FRONT WHEEL 7-3 

CHECKING THE FRONT WHEEL 7-3 

CHECKING THE BRAKE DISCS 7-5 

INSTALLING THE FRONT WHEEL 7-6 

ADJUSTING THE FRONT WHEEL STATIC BALANCE 7-6 

REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET .... 7-8 

REAR WHEEL 7-8 

BRAKE DISC AND REAR WHEEL SPROCKET 7-9 

REMOVING THE REAR WHEEL 7-11 

CHECKING THE REAR WHEEL 7-11 

CHECKING THE REAR WHEEL DRIVE HUB 7-12 

CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 7-12 

INSTALLING THE REAR WHEEL 7-13 

ADJUSTING THE REAR WHEEL STATIC BALANCE 7-13 

FRONT AND REAR BRAKES 7-14 

FRONT BRAKE PADS 7-14 

REAR BRAKE PADS 7-15 

REPLACING THE FRONT BRAKE PADS 7-16 

REPLACING THE REAR BRAKE PADS 7-18 

FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID 

RESERVOIR 7-21 

REAR BRAKE MASTER CYLINDER AND BRAKE FLUID 

RESERVOIR 7-24 

REMOVING THE FRONT BRAKE MASTER CYLINDER 7-26 

REMOVING THE REAR BRAKE MASTER CYLINDER 7-26 

CHECKING THE FRONT AND REAR BRAKE MASTER 

CYLINDERS 7-26 

INSTALLING THE FRONT BRAKE MASTER CYLINDER 7-27 

INSTALLING THE REAR BRAKE MASTER CYLINDER 7-29 

FRONT BRAKE CALIPERS 7-31 

REAR BRAKE CALIPER 7-33 

REMOVING THE FRONT BRAKE CALIPERS 7-35 

REMOVING THE REAR BRAKE CALIPER 7-36 

CHECKING THE FRONT AND REAR BRAKE CALIPERS 7-37 

INSTALLING THE FRONT BRAKE CALIPERS 7-38 

INSTALLING THE REAR BRAKE CALIPER 7-40 



CHAS 


(fiy® 



FRONT FORK 7-42 

REMOVING THE FRONT FORK LEGS 7-45 

DISASSEMBLING THE FRONT FORK LEGS 7-45 

CHECKING THE FRONT FORK LEGS 7-47 

ASSEMBLING THE FRONT FORK LEGS 7-48 

INSTALLING THE FRONT FORK LEGS 7-53 

HANDLEBARS 7-54 

REMOVING THE HANDLEBARS 7-56 

CHECKING THE HANDLEBARS 7-56 

INSTALLING THE HANDLEBARS 7-57 

STEERING HEAD 7-59 

LOWER BRACKET 7-59 

REMOVING THE LOWER BRACKET 7-61 

CHECKING THE STEERING HEAD 7-61 

INSTALLING THE STEERING HEAD 7-62 

REAR SHOCK ABSORBER ASSEMBLY 7-64 

HANDLING THE REAR SHOCK ABSORBER AND 

GAS CYLINDER 7-65 

DISPOSING OF A REAR SHOCK ABSORBER AND 

GAS CYLINDER 7-65 

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 7-66 

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND 

GAS CYLINDER 7-66 

CHECKING THE RELAY ARM AND CONNECTING ARM 7-67 

INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 7-67 

SWINGARM AND DRIVE CHAIN 7-68 

CHECKING THE SWINGARM 7-70 

REMOVING THE DRIVE CHAIN 7-70 

REMOVING THE SWINGARM 7-71 

CHECKING THE DRIVE CHAIN 7-73 

INSTALLING THE SWINGARM 7-75 

INSTALLING THE DRIVE CHAIN 7-75 



FRONT WHEEL AND BRAKE DISCS 



CHAS 



<?fc§ 



'© 



CHASSIS 
FRONT WHEEL AND BRAKE DISCS 




Order 



Job/Part 



Removing the front wheel and brake 
discs 



1 
2 
3 
4 
5 
6 
7 
8 



Brake hose holders (left and right) 

Front reflectors (left and right) 

Brake calipers (left and right) 

Wheel axle pinch bolt 

Front wheel axle 

Front wheel 

Collars (left and right) 

Brake discs (left and right) 



Q'ty 



Remarks 



Remove the parts in the order listed. 



2 
2 
2 
1 
1 
1 
2 
2 



NOTE: 

Place the motorcycle on a suitable stand 
so that the front wheel is elevated. 



Refer to "REMOVING/INSTALLING THE 
FRONT WHEEL". 

Loosen 

"i Refer to "REMOVING/INSTALLING THE 
^ FRONT WHEEL". 



For installation, reverse the removal 
procedure. 



7-1 



FRONT WHEEL AND BRAKE DISCS 



CHAS 



(fafc 



'© 




Order 



Job/Part 



Disassembling the front wheel 

© Oil seals (left and right) 

Wheel bearings (left and right) 
Spacer 



Q'ty 



2 
2 

1 



Remarks 



Remove the parts in the order listed. 



For assembly, reverse the disassembly 
procedure. 



7-2 



FRONT WHEEL AND BRAKE DISCS 



CHAS 



(2^ 



'0 



EA300521 

REMOVING THE FRONT WHEEL 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 



2. Remove: 

• Brake hose holders 
•front reflectors 

• left brake caliper 

• right brake caliper 
•wheel axle 



NOTE: — - 

Do not squeeze the brake lever when removing 
the brake calipers. 



3. Elevate: 
•front wheel 



NOTE: — 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 





eP 


ran 




v \i 

I2II1U701 



CHECKING THE FRONT WHEEL 

1. Check: 
•wheel axle 
Roll the wheel axle on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent wheel 
axle. 



2. Check: 

•tire 

•front wheel 
Damage/wear -+ Replace. 
Refer to "CHECKING THE TIRES" and 
"CHECKING THE WHEELS" in chapter 3. 



7-3 



FRONT WHEEL AND BRAKE DISCS 



CHAS 



(&G 




Measure: 

•radial wheel runout© 
• lateral wheel runout (2) 

Over the specified limits 



Replace. 




Front radial wheel runout 

1.0 mm (0.04 in) 
Front lateral wheel runout 

0.5 mm (0.02 in) 



Check: 
•wheel bearings 

Front wheel turns roughly or is loose 

place the wheel bearings, 
•oil seals 

Damage/wear -► Replace. 



Re- 



Replace: 
•wheel bearings 
•oil seals 



a. Clean the outside of the front wheel hub. 

b. Remove the oil seals © with a flat-head 
screwdriver. 



NOTE: 

To prevent damaging the wheel, place a rag (2) 
between the screwdriver and the wheel surface. 



c. Remove the wheel bearings (3) with a gener- 
al bearing puller. 

d. Install the new wheel bearings and oil seals 
in the reverse order of disassembly. 

CAUTION: 



Do not contact the wheel bearing center 
race® or balls©. Contact should be made 
only with the outer race (6) 

NOTE: 

Use a socket (7) that matches the diameter of 
the wheel bearing outer race and oil seal. 



7-4 



FRONT WHEEL AND BRAKE DISCS 




CHAS 



ofafc 



CHECKING THE BRAKE DISCS 

The following procedure applies to both of the 
brake discs. 

1. Check: 

• brake disc 
Damage/galling -+ Replace. 

2. Measure: 

• brake disc deflection 

Out of specification -► Correct the brake disc 
deflection or replace the brake disc. 



Max. brake disc deflection 
Front: 0.1 mm (0.0039 in) 
Rear: 0.1 mm (0.0039 in) 




a. 



Place the motorcycle on a suitable stand so 
that the wheel is elevated. 
Before measuring the front brake disc 
deflection, turn the handlebars to the left or 
right to ensure that the front wheel is station- 
ary. 
Remove the brake caliper. 

d. Hold the dial gauge at a right angle against 
the brake disc surface. 

e. Measure the deflection 1.5 mm (0.06 in) be- 
low the edge of the brake disc. 



b. 



c. 




3. Measure: 
•brake disc thickness 
Measure the brake disc thickness at a few 
different locations. 
Out of specification -► Replace. 




Min. brake disc thickness 
Front: 4.5 mm (0.18 in) 
Rear: 4.5 mm (0.18 in) 



Adjust: 
1 brake disc deflection 



a. Remove the brake disc. 

b. Rotate the brake disc by one bolt hole. 

c. Install the brake disc. 



NOTE: . 

Tighten the brake disc bolts in stages and in a 
crisscross pattern. 



7-5 



FRONT WHEEL AND BRAKE DISCS 



CHAS 



<£j& 



X 



% 



Brake disc bolt 

18Nm(1.8nvkg, 13fMb) 
LOCTITE® 



d. Measure the brake disc deflection. 

e. If out of specification, repeat the adjustment 
steps until the brake disc deflection is within 
specification. 

f . If the brake disc deflection cannot be brought 
within specification, replace the brake disc. 



INSTALLING THE FRONT WHEEL 

1. Lubricate: 
•wheel axle 
•oil seal lips 



Recommended lubricant 
Lithium soap base grease 




2. Tighten: 



> wheel axle © I XI 72 Nm ( 7 - 2 m>k 9. 52 ft,| b) 
•wheel axle pinch bolt (2) 



XI 20 Nm (2.0 nvkg, 14 ft«lb) 



CAUTION: 



Before tightening the wheel axle nut, push 
down hard on the handlebars several times 
and check if the front fork rebounds 
smoothly. 



3. Install: 
•brake calipers [XI 40 Nm ( 4 -° m * k 9' 29 ft,|b ) 

• front reflectors 

• brake hose holders 



A WARNING 



Make sure that the brake hose is routed 
properly. 



ADJUSTING THE FRONT WHEEL STATIC 
BALANCE 



NOTE: 

• After replacing the tire, wheel or both, the front 
wheel static balance should be adjusted. 

•Adjust the front wheel static balance with the 
brake discs installed. 



7-6 



FRONT WHEEL AND BRAKE DISCS 




1. Remove: 
•balancing weight(-s) 



CHAS 



efo§ 






2. Find: 
•front wheel's heavy spot 



a. Place the front wheel on a suitable balancing 
stand. 

b. Spin the front wheel. 

c. When the front wheel stops, put an "X^' mark 
at the bottom of the wheel. 

d. Turn the front wheel 90° so that the "X^' mark 
is positioned as shown. 

e. Release the front wheel. 

f . When the front wheel stops, put an "X 2 " mark 
at the bottom of the wheel. 

g. Repeat steps (a) through (d) several times 
until all the marks come to rest at the same 
spot. 

h. The spot where all the marks come to rest is 
the front wheel's heavy spot "X". 



3. Adjust: 
•front wheel static balance 

a. Install a balancing weight© onto the rim ex- 
actly opposite the heavy spot "X". 

NOTE: - 

Start with the lightest weight. 



b. Turn the front wheel 90° so that the heavy 
spot is positioned as shown. 

c. If the heavy spot does not stay in that posi- 
tion, install a heavier weight. 

d. Repeat steps (b) and (c) until the front wheel 
is balanced. 



4. Check: 
•front wheel static balance 



a. Turn the front wheel and make sure that it 
stays at each position shown. 

b. If the front wheel does not remain stationary 
at all of the positions, rebalance it. 



7-7 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 

REAR WHEEL 




XI 27 Nm (2.7 nvkg, 20 ft'lb) 



150 Nm (15 nvkg, 108 ft»lb)| (g^ 





40 Nm (4.0 nvkg, 29 ft'lb) 



2 3 



~I 




Order 



Job/Part 



Q'ty 



Remarks 



1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 



Removing the rear wheel 



Brake caliper 

Locknuts (left and right) 

Adjusting bolts (left and right) 

Wheel axle nut 

Washer 

Rear wheel axle 

Left adjusting block 

Right adjusting block 

Rear wheel 

Brake caliper bracket bolt 

Brake caliper bracket 



1 
2 
2 



Remove the parts in the order listed. 

NOTE: 

Place the motorcycle on a suitable stand 
so that the rear wheel is elevated. 



Loosen. 
Loosen. 



NOTE: 

Make sure that the tapered side of the right 
adjusting block faces the wheel. 



For installation, reverse the removal 
procedure. 



7-8 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



CHAS 



(3^ 



'© 



BRAKE DISC AND REAR WHEEL SPROCKET 



18Nm(1.8m»kg, 13ft»lb) 




69 Nm (6.9 nvkg, 50 ft'lb) 



Order 



1 
2 
3 
4 
5 
6 
7 
8 



Job/Part 



Removing the brake disc and rear 
wheel sprocket 

Brake disc 

Rear wheel sprocket 

Spacers (left and right) 

Oil seal 

Bearing 

Rear wheel drive hub 

Rear wheel drive hub dampers 

Rear wheel 



Q'ty 



1 
1 
2 
1 
1 
1 
5 
1 



Remarks 



Remove the parts in the order listed. 



For installation, reverse the removal 
procedure. 



7-9 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



CHAS 



<?fa§ 



'© 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the rear wheel 




Disassemble the parts in the order listed. 


® 


Spacer 






© 


Bearing 






® 


Spacer 






(4) 


Oil seal 






(D 


Circlip 






© 


Bearing 




For assembly, reverse the disassembly 
procedure. 



7-10 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



CHAS 



<3^ 



© 



REMOVING THE REAR WHEEL 

1. Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



2. Remove: 
• brake caliper 

NOTE: 

Do not depress the brake pedal when removing 
the brake caliper. 




3. Remove: 
•wheel axle nut 
•washer 
•wheel axle 
•adjusting blocks 

• brake caliper bracket. 

• rear wheel 



NOTE: 

Push the rear wheel forward and remove the 
drive chain from the rear wheel sprocket. 



CHECKING THE REAR WHEEL 

1. Check: 
•wheel axle 

• rear wheel 
•wheel bearings 
•oil seals 

• brake disc 

Refer to "BRAKE DISC AND REAR WHEEL 
SPROKET". 

2. Check: 
•tire 

• rear wheel 
Damage/wear -+ Replace. 

Refer to "CHECKING THE TIRES" and 
"CHECKING THE WHEELS" in chapter 3. 



7-11 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



CHAS 



efafc 



3. Measure: 

• radial wheel runout 

• lateral wheel runout 
Refer to "FRONT WHEEL". 

Over the specified limits -f Replace. 




Max. radial wheel runout 

1.0 mm (0.04 in) 
Max. lateral wheel runout 

0.5 mm (0.02 in) 




CHECKING THE REAR WHEEL DRIVE HUB 

1. Check: 

• rear wheel drive hub © 
Cracks/damage -+ Replace. 

• rear wheel drive hub dampers (2) 
Damage/wear -+ Replace. 



CHECKING AND REPLACING THE REAR 
WHEEL SPROCKET 

1. Check: 

• rear wheel sprocket 

More than 1 /4 tooth ® wear ->• Replace the 
rear wheel sprocket. 

Bent teeth — ► Replace the rear wheel sprock- 
et. 

(b) Correct 

© Drive chain roller 

(2) Rear wheel sprocket 

2. Replace: 

• rear wheel sprocket 

a. Remove the self-locking nuts and the rear 
wheel sprocket. 

b. Clean the rear wheel drive hub with a clean 
cloth, especially the surfaces that contact the 
sprocket. 

c. Install the new rear wheel sprocket. 



\, 



\ 



Rear wheel sprocket self-locking 
nut 

69 Nm (6.9 nvkg, 50 ft-lb) 



NOTE: 

Tighten the self-locking nuts in stages and in a 
crisscross pattern. 



7-12 



REAR WHEEL, BRAKE DISC, AND REAR WHEEL 

SPROCKET 



CHAS 



<£% 



'© 



EAS00571 

INSTALLING THE REAR WHEEL 

1. Lubricate: 
•wheel axle 
•wheel bearings 
•oil seal lips 



Recommended lubricant 
Lithium soap base grease 




2. Install: 

• rear wheel 

•brake caliper bracket 
•adjusting blocks 
•wheel axle 
•washer 
•wheel axle nut 

• brake caliper 



3. Adjust: 
•drive chain slack® 




Drive chain slack 

40 ~ 50 mm (1.57 ~ 1.97 in) 



Refer to "ADJUSTING THE DRIVE CHAIN 
SLACK" in chapter 3. 
4. Tighten: 



•wheel axle nut X 15 ° Nm OS.o m«kg, i08ft«ib) 


• brake caliper bolts 


X 27 Nm (2.7 nvkg, 20 ft-lb) 


• brake caliper bracket bolt 


X 40 Nm (4.0 rmkg, 29 ft-lb) 




Ak WARNING! 



Make sure that the brake hose is routed 
properly. 



ADJUSTING THE REAR WHEEL STATIC 
BALANCE 

NOTE: 

•After replacing the tire, wheel or both, the rear 
wheel static balance should be adjusted. 

•Adjust the rear wheel static balance with the 
brake disc and rear wheel drive hub installed. 

1. Adjust: 
• rear wheel static balance 
Refer to "FRONT WHEEL". 



7-13 



FRONT AND REAR BRAKES 



CHAS 



<£% 



FRONT AND REAR BRAKES 

FRONT BRAKE PADS 




XI 40 Nm (4.0 m»kg, 29 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the front brake pads 




Remove the parts in the order listed. 
The following procedure applies to both 
of the front brake calipers. 


1 


Brake pad clips 


2 - 




2 


Brake pad pin 


1 




3 


Brake pad spring 


1 


Refer to "REPLACING THE FRONT 


4 


Brake pads 


2 


BRAKE PADS". 


5 


Brake pad shims 


2 




6 


Bleed screw 


1 - 


For installation, reverse the removal 
procedure. 



7-14 



FRONT AND REAR BRAKES 



CHAS 



(3^6 



'© 



REAR BRAKE PADS 





27 Nm (2.7 nrrkg, 
20 ft»lb) 



40 Nm (4.0 nvkg, 29 ft»lb) 



Order 


Job/Part 


Q'ty 


Remarks 


1 
2 
3 
4 


Removing the rear brake pads 

Brake caliper bolts 
Brake pads 
Brake pad shims 
Bleed screw 


2 - 
2 
4 
1 - 


Remove the parts in the order listed. 

Refer to "REPLACING THE REAR 
BRAKE PADS". 

For installation, reverse the removal 
procedure. 



7-15 



FRONT AND REAR BRAKES 




CAUTION: 



Disc brake components rarely require dis- 
assembly. 

Therefore, always follow these preventive 
measures: 

• Never disassemble brake components un- 
less absolutely necessary. 

• If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after 
reassembly. 

• Never use solvents on internal brake com- 
ponents. 

• Use only clean or new brake fluid for clean- 
ing brake components. 

• Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

• Avoid brake fluid coming into contact with 
the eyes as it can cause serious injury. 

First aid for brake fluid entering the eyes: 

• Flush with water for 1 5 minutes and get im- 
mediate medical attention. 




REPLACING THE FRONT BRAKE PADS 

The following procedure applies to both brake 
calipers. 

NOTE: 

When replacing the brake pads, it is not neces- 
sary to disconnect the brake hose or disas- 
semble the brake caliper. 

1. Remove: 

• brake hose holder bolt® 

• front ref rector (2) 

• brake caliper® 



7-16 



FRONT AND REAR BRAKES 










Q 


p 










■ 


' 




T 


N 


s 


-) 


V 


N 


it ^ 




12221)404 



CHAS 



(&& 



r © 



2. Remove: 
•brake pad clips© 
•brake pad pins© 
•brake pad spring® 
• brake pads 
(along with the brake pad shims) 



3. Measure: 
•brake pad wear limit© 
Out of specification -+ Replace the brake 
pads as a set. 




Brake pad wear limit 
0.5 mm (0.02 in) 



4. Install: 
•brake pad shims 
(onto the brake pads) 
• brake pads 
•brake pad spring 

NOTE: 



Always install new brake pads, brake pad 
shims, and a brake pad spring as a set. 




a. Connect a clear plastic hose © tightly to the 
bleed screw© . Put the other end of the hose 
into an open container. 

b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with 
your finger. 

c. Tighten the bleed screw. 



V 



\ 



Bleed screw 

6 Nm (0.6 nrkg, 4.3 fWb) 



d. Install a new brake pad shim onto each new 
brake pads. 

e. Install new brake pads and a new brake pad 
spring. 

NOTE: 

The arrow @ on the brake pad spring must 
point in the direction of disc rotation. 



7-17 



FRONT AND REAR BRAKES 



CHAS 



<£y& 



5. Install: 
•brake pad pins 
•brake pad clips 
• brake caliper bolts 



40 Nm (4.0 nvkg, 29 ft'lb) 



'brake hose holder bolt 



6 Nm (0.6 nvkg, 4.3 fHb) 




Check: 

'brake fluid level 

Below the minimum level mark (a) -► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



7. Check: 
• brake lever operation 
Soft or spongy feeling -+ Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 




REPLACING THE REAR BRAKE PADS 



NOTE: 

When replacing the brake pads, it is not neces- 
sary to disconnect the brake hose or disas- 
semble the brake caliper. 

1. Remove: 
•brake caliper© 

2. Remove: 
•brake pads 

(along with the brake pad shims) 



7-18 



FRONT AND REAR BRAKES 




CHAS 



<&& 



3. Measure: 
• brake pad wear limit ® 
Out of specification -+ Replace the brake 
pads as a set. 




Brake pad wear limit 
0.8 mm (0.03 in) 



4. Install: 

• brake pad shims 
(onto the brake pads) 

• brake pads 

NOTE: 



Always install new brake pads, brake pad 
shims, and a brake pad spring as a set. 




a. Connect a clear plastic hose © tightly to the 
bleed screw®. Put the other end of the hose 
into an open container. 

b. Loosen the bleed screw and push the brake 
caliper pistons into the brake caliper with 
your finger. 

c. Tighten the bleed screw. 



V 



\ 



Bleed screw 

6 Nm (0.6 nvkg, 4.3 fMb) 



d. Install a new brake pa shim onto each new 
brake pad. 



7-19 



FRONT AND REAR BRAKES 



CHAS 



(^ 



5. Install: 

• brake caliper bolts 

W\ 27 Nm (2.7 nvkg, 20 ftMbj" 




6. Check: 
• brake fluid level 
Below the minimum level mark® —► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



7. Check: 
• brake pedal operation 
Soft or spongy feeling -► Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



7-20 



FRONT AND REAR BRAKES 



CHAS 



ofcg 



r © 



FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 



30 Nm (3.0 nvkg, 22 ft»lb) 

2 



13Nm(1.3m«g, 9.4 fHb) 



Order 



Job/Part 



1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 



Removing the front brake master 
cylinder and brake fluid reservoir 

Brake fluid 

Brake fluid reservoir cap stopper 

Brake fluid reservoir cap 

Brake fluid reservoir diaphragm holder 

Brake fluid reservoir diaphragm 

Brake fluid reservoir 

Brake fluid reservoir hose 

Circlip 

Dust cover 

Hose joint 

Brake lever 

Front brake switch connector 

Union bolt 

Copper washer 



Q'ty 



2 
1 
3 



Remarks 




Remove the parts in the order listed. 
Drain. 



I] 



Disconnect. 

Refer to "INSTALLING THE FRONT 
BRAKE MASTER CYLINDER". 



7-21 



FRONT AND REAR BRAKES 




30 Nm (3.0 nvkg, 22 ft«lb) 
2 




13Nm(1.3nrg, 9.4 fHb) 



Order 


Job/Part 


Q'ty 


Remarks 


14 
15 
16 
17 


Brake hose 

Brake master cylinder holder 
Brake master cylinder 
Front brake switch 


2 - 
1 

1 - 
1 


" Refer to "INSTALLING THE FRONT 
. BRAKE MASTER SYLINDER". 

For installation, reverse the removal 
procedure. 



7-22 



FRONT AND REAR BRAKES 



CHAS 



o^6 



r © 




Order 



Job/Part 



Disassembling the front brake 
master cylinder 

© Dust boot 
(2) Circlip 

Brake master cylinder kit 

Brake master cylinder 



Q'ty 



Remarks 



Remove the parts in the order listed. 



For assembly, reverse the disassembly 
procedure. 



7-23 



FRONT AND REAR BRAKES 



CHAS 



efa§ 



REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 




5 Nm (0.5 nvkg, 3.6 fHb) 



XI 23 Nm (2.3 m»kg, 17 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the rear brake master 




Remove the parts in the order listed. 




cylinder and brake fluid reservoir 








Brake fluid 




Drain. 


1 


Brake fluid reservoir cap 






2 


Brake fluid reservoir diaphragm holder 






3 


Brake fluid reservoir diaphragm 






4 


Brake fluid reservoir 






5 


Brake fluid reservoir hose 






6 


Hose joint 






7 


Union bolt 






8 


Copper washer 


2 


Refer to "INSTALLING THE REAR 


9 


Brake hose 




BRAKE MASTER SYLINDER". 


10 


Brake master cylinder 




For installation, reverse the removal 
procedure. 



7-24 



FRONT AND REAR BRAKES 



CHAS 



<&& 



xs> 




Order 



Job/Part 



Disassembling the rear brake 
master cylinder 

© Brake master cylinder kit 
(2) Brake master cylinder 



Q'ty 



Remarks 



Remove the parts in the order listed. 



For assembly, reverse the disassembly 
procedure. 



7-25 



FRONT AND REAR BRAKES 



CHAS 



ofafc 




EAS00S88 

REMOVING THE FRONT BRAKE MASTER 
CYLINDER 

NOTE: 

Before disassembling the front brake master 
cylinder, drain the brake fluid from the entire 
brake system. 

1. Remove: 
•union bolt© 

• copper washers (2) 

• brake hoses (3) 

• master cylinder holder (4) 

NOTE: 

To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose. 




REMOVING THE REAR BRAKE MASTER 
CYLINDER 

1. Remove: 

• union bolt© 

• copper washers (2) 

• brake hose (3) 

• button head bolts (4) 

NOTE: 

To collect any remaining brake fluid, place a 
container under the master cylinder and the end 
of the brake hose. 



CHECKING THE FRONT AND REAR BRAKE 
MASTER CYLINDERS 

The following procedure applies to both of the 
brake master cylinders. 
1. Check: 
•brake master cylinder 

Damage/scratches/wear — ► Replace, 
•brake fluid delivery passages 
(brake master cylinder body) 
Obstruction ~+ Blow out with compressed air. 

\E Front 

M Rear 



7-26 



FRONT AND REAR BRAKES 



CHAS 



#5§ 



r © 




2. Check: 
•brake master cylinder kit 
Damage/scratches/wear 
51 Front 
[S Rear 



Replace. 



3. Check: 

•brake fluid reservoir© 
Cracks/damage -► Replace. 

•brake fluid reservoir diaphragm (2) 
Cracks/damage -*- Replace. 

4. Check: 

• brake hoses 
Cracks/damage/wear -+- Replace. 



INSTALLING THE FRONT BRAKE MASTER 
CYLINDER 



A WARNING 



• Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

•Never use solvents on internal brake com- 
ponents. 



*& 



Recommended brake fluid 
DOT 4 



7-27 



FRONT AND REAR BRAKES 



CHAS 



efas 




1. Install: 

• brake master c ylinder® 

P\l 13 Nm (1 .3 nrkg, 9.4 fHb) 



•brake master cylinder holder 
NOTE: 



• Install the brake master cylinder holder with 
the "UP" mark facing up. 

•Align the end of the brake master cylinder 
holder with the punch mark (§) in the right han- 
dlebar. 

•First, tighten the upper bolt, then the lower 
bolt. 



2. Install: 
•copper washers 
• brake hose 
•union bolt 



A WARNING 



30 Nm (3.0 rrvkg, 22 fHb) 




Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING ". 



NOTE: 

•While holding the brake hose, tighten the 

union bolt as shown. 
•Turn the handlebars to the left and to the right 

to make sure that the brake hose does not 

touch other parts (e.g., wire harness, cables, 

leads). Correct if necessary. 

3. Fill: 
•brake fluid reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



•ft 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

•When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vanor lock. 



7-28 



FRONT AND REAR BRAKES 




CHAS 



<?fa§ 



'© 



CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

4. Bleed: 

• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

5. Check: 
•brake fluid level 

Below the minimum level mark® -+ Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



6. Check: 
• brake lever operation 
Soft or spongy feeling 
system. 
Refer to "BLEEDING 



Bleed the brake 



THE HYDRAULIC 



BRAKE SYSTEM" in chapter 3. 




INSTALLING THE REAR BRAKE MASTER 
CYLINDER 

1. Install: 
•copper washers 

• brake hoses 

• union bolt 

• button head bolts 



A WARNING 



30 Nm (3.0 m«kg, 22 ft«lb) 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 



CAUTION: 



When installing the brake hose onto the 
brake master cylinder, make sure that the 
brake pipe touches the projection ® as 
shown. 



7-29 



FRONT AND REAR BRAKES 



CHAS 



(£y& 




2. Fill: 
•brake fluid reservoir 



*Q> 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

•When refilling, be careful that water does 
not enter the reservoir. Water will signifi- 
cantly lower the boiling point of the brake 
fluid and could cause vapor lock. 

CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

3. Bleed: 

• brake system 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

4. Check: 
•brake fluid level 

Below the minimum level mark® -* Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 

5. Adjust: 

• brake pedal position 

Refer to "ADJUSTING THE REAR BRAKE" 
in chapter 3. 




Brake pedal position (from the 
top of the brake pedal to the bot- 
tom of the rider footrest bracket 
bolt center) 

4.3 ~ 9.3 mm (0.17 ~ 0.37 in) 



6. Adjust: 
• rear brake light operation timing 
Refer to "ADJUSTING THE REAR BRAKE 
LIGHT SWITCH" in chapter 3. 



7-30 



FRONT AND REAR BRAKES 



CHAS 



<?fcs 



FRONT BRAKE CALIPERS 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the front brake calipers 




Remove the parts in the order listed. 




Brake fluid 




The following procedure applies to both 

of the front brake calipers. 

Drain. 


1 


Front refrector 


1 




2 


Union bolt 


1 - 




3 
4 
5 


Copper washer 
Brake hose 
Brake caliper 


2 
1 
1 - 


Refer to "INSTALLING THE FRONT 
BRAKE CALIPERS". 

For installation, reverse the removal 
procedure. 



7-31 



FRONT AND REAR BRAKES 



CHAS 



<£% 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the front brake 




Disassemble the parts in the order listed. 




calipers 




The following procedure applies to both 
of the front brake calipers. 


© 


Brake pad clip 


2 




(2) 


Brake pad pin 


1 




® 


Brake pad spring 


1 




(4) 


Brake pad 


2 - 




© 


Brake caliper piston 


4 


Refer to "REMOVING THE FRONT 


(6) 


Brake caliper piston seal 


8 


BRAKE CALIPERS". 


® 


Bleed screw 


1 - 


For assembly, reverse the disassembly 
procedure. 



7-32 



FRONT AND REAR BRAKES 



CHAS 



cfije 



r © 



REAR BRAKE CALIPER 



/"~ 



30 Nm (3.0 nvkg, 22 ft«lb) 




27 Nm (2.7 nvkg, 
20 ft»lb) 




Order 



1 
2 
3 

4 



Job/Part 



Removing the rear brake caliper 

Brake fluid 
Union bolt 
Copper washer 
Brake hose 
Brake caliper 



Q'ty 



1 
2 
1 
1 



Remarks 



Remove the parts in the order listed. 
Drain. 

Refer to "INSTALLING THE REAR 
BRAKE CALIPERS". 

For installation, reverse the removal 
procedure. 



7-33 



FRONT AND REAR BRAKES 



CHAS 



(&G 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the rear brake caliper 




Disassemble the parts in the order listed. 


® 


Brake pad 


2 




© 


Brake caliper piston 


2 -, 


1 Refer to "REMOVING THE REAR 
J BRAKE CALIPERS". 


(3) 


Brake caliper piston seal 


4 i 


(4) 


Bleed screw 


1 


For assembly, reverse the disassembly 
procedure. 



7-34 



FRONT AND REAR BRAKES 



CHAS 



(£jQ 



'© 




REMOVING THE FRONT BRAKE CALIPERS 

The following procedure applies to both of the 
brake calipers. 

NOTE: 

Before removing either brake caliper, drain the 
brake fluid from the entire brake system. 

1. Remove: 
•front refrector© 
•union bolt (2) 

• copper washers (3) 

• brake hose (4) 
•brake caliper (5) 

NOTE: 

Put the end of the brake hose into a container 
and pump out the brake fluid carefully. 

2. Remove: 

• brake caliper pistons © 
•brake caliper piston seals (2) 

a. Secure the right side brake caliper pistons 
with a piece of wood (a). 

b. Blow compressed air into the brake hose 
joint opening (b) to force out the pistons from 
the brake caliper. 



A WARNING 



• Never try to pry out the brake caliper pis- 
tons. 

• Do not loosen the bolts (3). 



c. Remove the brake caliper piston seals. 

d. Repeat the previous steps to force out the 
right side pistons from the brake caliper. 



7-35 



FRONT AND REAR BRAKES 



CHAS 



ofafc 



EAS00628 

REMOVING THE REAR BRAKE CALIPER 



NOTE: 

Before removing the brake caliper, drain the 
brake fluid from the entire brake system. 




1. Remove: 
•union bolt© 
•copper washers* 
• brake hose (3) 



NOTE: 

Put the end of the brake hose into a container 
and pump out the brake fluid carefully. 



2. Remove: 
• brake caliper pistons (T) 
•brake caliper piston seals (2) 

a. Blow compressed air into the brake hose 
joint opening ® to force out the pistons from 
the brake caliper. 

Be careful not to get injured when the pistons 
are expelled from the brake caliper.. 



A WARNING 



•Cover the brake caliper piston with a rag. 
• Never try to pry out the brake caliper pis- 
tons. 

b. Remove the brake caliper piston seals. 



7-36 



FRONT AND REAR BRAKES 



CHAS 



d&G 



'0 



CHECKING THE FRONT AND REAR BRAKE 
CALIPERS 



AT 





Recommended brake component 
replacement schedule 


Brake pads 


If necessary 


Piston seals 


Every two years 


Brake hoses 


Every four years 


Brake fluid 


Every two years and 
whenever the brake 
is disassembled 



1. Check: 
•brake caliper pistons © 
Rust/scratches/wear -t- Replace the brake 
caliper. 

• brake caliper cylinders (2) 
Scratches/wear -+ Replace the brake cali- 
per. 

• brake calipers (3) 
Cracks/damage -+ Replace. 

• brake fluid delivery passages 
(brake caliper body) 

Obstruction —► Blow out with compressed air. 



A WARNING 



Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. 

[A] Front 
\B\ Rear 



©- 




Jo) 






/Cy\ 








Mt^ 








P( ( 


Si 






\q\V- 




oL- — -r 




V^c 


o^o 


WJ 



2. Check: 
• rear brake caliper bracket © 
Cracks/damage -+ Replace. 



7-37 



FRONT AND REAR BRAKES 



CHAS 



ofafc 



INSTALLING THE FRONT BRAKE CALIPERS 

The following procedure applies to both of the 
brake calipers. 



A WARNING 



• Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

• Never use solvents on internal brake com- 
ponents as they will cause the piston seals 
to swell and distort. 

• Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. 



*Q 



Recommended brake fluid 
DOT 4 




1. Install: 
•brake caliper® 
(temporarily) ^^^ 

• copper washers BEM 

• brake hose (2) 
•union bolt® 



30 Nm (3.0 nvkg, 22 ft'lb) 



A WARNING 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING ". 



CAUTION: 



When installing the brake hose onto the 
brake caliper ®, make sure that the brake 
pipe (a) touches the projection © on the 
brake caliper. 



Remove: 
'brake caliper 

Install: 
'brake pads 
'brake pad spring 
'brake caliper 
•front ref rector 



40 Nm (4.0 nvkg, 29 ft»lb) 



• brake hose holder 



6 Nm (0.6 nvkg, 4.3 ft'lb) 



Refer to "REPLACING THE FRONT BRAKE 
PADS". 



7-38 



FRONT AND REAR BRAKES 



CHAS 



efc§ 




4. Fill: 
•brake fluid reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



•Y> 



Recommended brake fluid 
DOT 4 



A WARNING 



• Use only the designated brake fluid. Other 
brake fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

•When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 

CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

5. Bleed: 

• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

6. Check: 
•brake fluid level 

Below the minimum level mark® -+ Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



7. Check; 
• brake lever operation 
Soft or spongy feeling -+ Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



7-39 



FRONT AND REAR BRAKES 




EAS00642 

INSTALLING THE REAR BRAKE CALIPER 



A WARNING 



• Before installation, all internal brake com- 
ponents should be cleaned and lubricated 
with clean or new brake fluid. 

• Never use solvents on internal brake com- 
ponents as they will cause the piston seals 
to swell and distort. 

• Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals. 



*L> 



Recommended brake fluid 
DOT 4 





i(D|®\ 


. (a) \\X 


*\f 









1. Install: 

• brake pads 
•brake caliper® 
•copper washers 

• brake hose (2) 
•union bolt (3) 



A WARNING 



30 Nm (3.0 nvkg, 22 ft«lb) 



Proper brake hose routing is essential to in- 
sure safe motorcycle operation. Refer to 
"CABLE ROUTING". 



CAUTION: 



When installing the brake hose onto the 
brake caliper (D, make sure that the brake 
pipe (D touches the projection © on the 
brake caliper. 



7-40 



FRONT AND REAR BRAKES 



CHAS 



d&& 




2. Fill: 
• brake fluid reservoir 
(with the specified amount of the recom- 
mended brake fluid) 



'tt 



Recommended brake fluid 
DOT 4 



A WARNING 



•Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage and 
poor brake performance. 

• Refill with the same type of brake fluid that 
is already in the system. Mixing brake 
fluids may result in a harmful chemical 
reaction, leading to poor brake perfor- 
mance. 

•When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor lock. 

CAUTION: 



Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately. 

3. Bleed: 

• brake system 
Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 

4. Check: 
•brake fluid level 

Below the minimum level mark (a) _► Add the 
recommended brake fluid to the proper level. 
Refer to "CHECKING THE BRAKE FLUID 
LEVEL" in chapter 3. 



5. Check: 
•brake pedal operation 
Soft or spongy feeling -+ Bleed the brake 
system. 

Refer to "BLEEDING THE HYDRAULIC 
BRAKE SYSTEM" in chapter 3. 



7-41 



FRONT FORK 



FRONT FORK 



CHAS 


(&® 



33 Nm (3.3 rrvkg, 24 ft-lb) 



26 Nm (2.6 m»kg, 19ft»lb) 



23 Nm (2.3 nvkg, 17ft»lb) 



23 Nm (2.3 m»kg, 17ft» 



6 Nm (0.6 m»kg, 
4.3 ft'lb) 




XI 6 Nm (0.6 m«kg, 4.3 fHb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the front fork legs 




Remove the parts in the order listed. 




Front brake calipers 




The following procedure applies to both 
of the front fork legs. 




Front wheel 




Refer to "FRONT WHEEL AND BRAKE 
DISCS". 




Front cowling inner panel 




Refer to "COWLINGS" in chapter 3. 


1 


Front fender 


1 




2 


Handlebar pinch bolt 


2 


Loosen 


3 


Upper bracket bolt 


2 




4 


Handlebar (left) 


1 




5 


Handlebar (right) 


1 




6 


Cap bolts 


2 


Loosen 


7 


Upper bracket pinch bolts 


2 


Loosen 


8 


Lower bracket pinch bolts 


4 


Loosen 


9 


Front fork legs 


2 


For installation, reverse the removal 
procedure. 



7-42 



FRONT FORK 



CHAS 



ofafc 



'© 



XI 23 Nm (2.3 m»kg, 17 ft»lb) 



© 6 




40 Nm (4.0 m«kg, 29 ft«lb) 



Order 



Job/Part 



Disassembling the front fork legs 



© Cap bolt 
(2) O-ring 

Nut 

Washer 

Spacer 

Washer 

Fork spring 

Copper washer 

Damper rod assembly bolt 

Damper rod assembly 



Q'ty 



Remarks 



Remove the parts in the order listed. 
The following procedure applies to both of 
the front fork legs. 



Refer to "DISASSEMBLING/ 
ASSEMBLING THE FRONT FORK 
LEGS". 



7-43 



FRONT FORK 



CHAS 



<fafc 



23 Nm (2.3 nvkg, 17fHb) 



4t) ISHW 




40 Nm (4.0 nrkg, 29 ft»lb) 



Order 


Job/Part 


Q'ty 


Remarks 


© 


Dust seal 






© 


Oil seal clip 






© 


Oil seal 




Refer to "DISASSEMBLING/ 


© 


Washer 




ASSEMBLING THE FRONT FORK 


© 


Outer tube bushing 




LEGS". 


© 


Inner tube 






© 


Oil lock piece 




For assembly, reverse the disassembly 
procedure. 



7-44 




FRONT FORK 



CHAS 



(£jQ 



'0 



EAS00649 



REMOVING THE FRONT FORK LEGS 

The following procedure applies to both of the 

front fork legs. 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: 

Place the motorcycle on a suitable stand so that 
the front wheel is elevated. 

2. Loosen: 

• upper bracket pinch bolt © 
•cap bolt© 

•handlebar pinch bolt© 
•lower bracket pinch bolt 

• upper bracket bolt (4) 
•handlebar© 



A WARNING 



Before loosening the upper and lower 
bracket pinch bolts and handlebar pinch 
bolt, support the front fork leg. 

3. Remove: 
•front fork leg 




EAS00655 



DISASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Remove: 

•cap bolt© 
(from the damper adjusting rod) 

•spacer© 

•nut© 

a. Press down on the spacer with the fork 
spring compressor®. 

b. Install the rod holder© between the nut© 
and the spacer©. 



¥- 



Fork spring compressor 

90890-01441 
Rod holder 

90890-01434 



7-45 



FRONT FORK 



CHAS 



(^ 



NOTE: 

Use the side of the rod holder that is marked "B". 

c. Loosen the nut. 

d. Remove the cap bolt. 

e. Remove the rod holder and fork spring com- 
pressor. 



A WARNING 



The fork spring is compressed. 

f. Remove the spacer and nut. 

g. Remove the fork spring. 




2. Drain: 
•fork oil 



NOTE: 

Stroke the damper rod © several times while 
draining the fork oil. 



3. Remove: 
•dust seal 
•oil seal clip© 
•oil seal 
•washer 
(with a flat-head screwdriver) 
•Slide metal 



4. Remove: 
•damper rod assembly bolt 
•copper washer 

NOTE: 



While holding the damper rod with the damper 
rod holder©, loosen the damper rod assembly 
bolt. 



7-46 



?> 



Damper rod holder 

90890-01425, YM-01 425 




FRONT FORK 



CHAS 



(&G 



EAS00657 



CHECKING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 
1. Check: 

•inner tube® 

• outer tube (2) 
Bends/damage/scratches -+ Replace. 



A WARNING 



Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it. 




2. Measure: 
•spring free length® 
Out of specification - 



Replace. 




Spring free length limit 
251 .8 mm (9.91 in) 
<Limit>: 246 mm (9.69 in) 



3. Check: 
•damper rod© 
Damage/wear -► Replace. 
Obstruction -► Blow out all of the oil 
sages with compressed air. 

CAUTION: 



pas- 



• The front fork leg has a built-in damper ad- 
justing rod and a very sophisticated inter- 
nal construction, which are particularly 
sensitive to foreign material. 

•When disassembling and assembling the 
front fork leg, do not allow any foreign ma- 
terial to enter the front fork. 



7-47 



FRONT FORK 



CHAS 



(&£ 




4. Check: 
•cap bolt O-ring 
Damage/wear - 



Replace. 



ASSEMBLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 



A WARNING 




•Make sure that the oil levels in both front 
fork legs are equal. 

• Uneven oil levels can result in poor han- 
dling and a loss of stability. 

NOTE: 

• When assembling the front fork leg, be sure to 
replace the following parts: 

- inner tube bushing 

- outer tube bushing 

- oil seal 

- dust seal 

• Before assembling the front fork leg, make 
sure that all of the components are clean. 

1. Install: 
•oil lock piece 
•inner tube(2) 
• damper rod assembly (T) 



A WARNING 



Always use new copper washers. 



CAUTION: 



Allow the damper rod assembly to slide 
slowly down the inner tube (2) until it pro- 
trudes from the bottom of the inner tube. Be 
careful not to damage the inner tube. 

2. Lubricate: 
• inner tube's outer surface 



Recommended lubricant 

Yamaha fork and suspension oil 
01 or equivalent 



7-48 






J L 








i^] 






S 


-J=sJ 

6Ht 




FRONT FORK 



CHAS 



T 



<£y& 



3. Tighten: mm 

•damper rod assembly bolt© m*M 



40 Nm (4.0 nvkg, 29 ft»lb) 



NOTE: 

While holding the damper rod with the damper 
rod holder©, tighten the damper rod assembly 
bolt. 




Damper rod holder 

90890-01425, YM-01425 



X. Install: 
•outer tube bushing © 
• washer (2) 
•oil seal® 
•oil seal clip® 
•dust seal© 

CAUTION: 



Make sure that the numbered side of the oil 
seal faces up. 



NOTE: 

•Before installing the oil seal, lubricate its lips 

with lithium soap base grease. 
•Lubricate the outer surface of the inner tube 

with fork oil. 
•Before installing the oil seal, cover the top of 

the front fork leg with a plastic bag© to protect 

the oil seal during installation. 



5. Install: 
•washer 
•oil seal© 
(with the fork seal driver (2 




Fork seal driver weight 
90890-01367, YM-33963 

Fork seal driver attachment 
90890-01374, YM-8020 



6. Install: 
•oil seal clip© 

NOTE: 



Adjust the oil seal clip so that it fits into the outer 
tube's groove. 



7-49 



FRONT FORK 



CHAS 



<3^ 















(?) 








\£) 









7. Install: 
•dust seal® 
(with the fork seal driver (2)) 




8. Install: 
•rod puller© 
•adapter© 
(onto the damper rod 



¥- 



Rod puller 

90890-01437, YM-01 437 
Adapter 

90890-01436 



9. Fully compress the front fork leg. 

10. Fill: 

• front fork leg 
(with the specified amount of the recom- 
mended fork oil) 



•t> 



Quantity (each front fork leg) 

476 cm 3 (16.09356 US oz) 
Recommended oil 

Yamaha fork and suspension 

oil 01 

or equivalent 



CAUTION: 



• Be sure to use the recommended fork oil. 
Other oils may have an adverse effect on 
front fork performance. 

• When disassembling and assembling the 
front fork leg, do not allow any foreign ma- 
terial to enter the front fork. 




11 . After filling the front fork leg, slowly stroke 
the damper rod © up and down (at least ten 
times) to distribute the fork oil. 

NOTE: 

Be sure to stroke the damper rod slowly be- 
cause the fork oil may spurt out. 



7-50 




FRONT FORK 



CHAS 



*fc% 



1 2. Slowly stroke the inner tube® up and down 
to distribute the fork oil once more (1 stroke 
= about 100 mm (3.94 in)). 

NOTE: 

Be careful not to stroke the inner tube over 1 00 
mm (3.94 in) as this will cause air to enter. If the 
inner tube is stroked more than 100 mm (3.94 
in), repeat steps (12) and (13). 

1 3. Before measuring the fork oil level, wait ten 
minutes until the oil has settled and the air 
bubbles have dispersed. 

NOTE: 

Be sure to bleed the front fork leg of any residual 
air. 





— I n a 

r ® 

T 

\ 
/ 




12311404 




14. Measure: 
•front fork leg oil level ® 
Out of specification -+ Correct. 




Front fork leg oil level (from the 
top of the inner tube, with the 
inner tube fully compressed, 
and without the spring) 
107 mm (4.21 in) 



15. Install: 
•nut® 

•fork spring© 
•washer® 
•spacer® 
•washer® 

•damper adjusting rod ' 
•cap bolt® 



a. Remove the rod puller and adapter. 

b. Install the nut. 



7-51 



FRONT FORK 




c. Install the rod puller and adapter onto the 
damper rod. 



¥- 



Rod puller 

90890-01437, YM-01437 
Adapter 

90890-01436 



J/ 
/ft/ 


'*g"gj 


14) 



d. Install the fork spring, washers and spacer. 

e. Press down on the spacer with the fork 
spring compressor®. 

f . Pull up the rod puller and install the rod hold- 
er© between the nut© and the spacer®. 

NOTE: 

Use the side of the rod holder that is marked "B". 




Fork spring compressor 

90890-01441 
Rod holder 

90890-01434 



1 




-BL - — ^- 


sfisT"^ 


r jpc^ 




n r 



g. Remove the rod puller and adapter. 

h. Install the nut© and position it as specified 




Distance ® 

25 mm (0.98 in) 



i. Install the damper adjusting rod and cap bolt, 
and then finger tighten the cap bolt. 

j. Hold the cap bolt and tighten the nut to speci- 
fication. 



X 



\ 



Nut: 

15Nm(1.5m»kg, 11 fHb) 



k. Remove the rod holder and fork spring com- 
pressor. 



A WARNING 



•The fork spring is compressed. 
•Always use a new cap bolt O-ring. 



7-52 




FRONT FORK 



CHAS 



<?fc§ 



16. Install: 
• cap bolt 
(onto the inner tube) 

NOTE: 



Temporarily tighten the cap bolt. 



INSTALLING THE FRONT FORK LEGS 

The following procedure applies to both of the 
front fork legs. 

1. Install: 
•front fork leg 

Temporarily tighten the upper and lower 
bracket pinch bolts. 

NOTE: 

Make sure that the inner fork tube is flush with 
the top of the handlebar. 

2. Tighten: 
■lower bracket pi nch bolt 





X 23 Nm (2.3 nvkg, 


17ft 


•lb) 


•handlebar pinch bolt© 




XI 33 Nm (3.0 nvkg, 


24 ft 


•lb) 


•cap bolt© 


X 23 Nm (2.3 nvkg, 


17ft 


•lb) 


• upper bracket pinch bolt (3) 




IX 26 Nm (2.6 nvkg, 


19ft 


•lb) 












A WARNING 





Make sure that the brake hoses are routed 
properly. 



3. Adjust: 
•spring preload 
•rebound damping 
•compression damping 

Refer to "ADJUSTING THE FRONT FORK 

LEGS" in chapter 3. 



7-53 



HANDLEBARS 



CHAS 



(&e 



HANDLEBARS 



X|150 Nm (11.5 m»kg, 83 1Mb) 



13Nm(1.3m»kg, 9.4ft«lb) 



13Nm(1.3m»kg, 9.4ft»lb) 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the handlebars 




Remove the parts in the order listed. 


1 


Left grip end 


1 - 
1 - 


1 Refer to "REMOVING/INSTALLING THE 


2 


Handlebar grip 


J HANDLEBARS". 


3 


Clutch switch connector 


2 


Disconnect. 


4 


Left handlebar switch 


1 


Refer to "INSTALLING THE 
HANDLEBARS". 


5 


Starter cable 


1 


Disconnect. 


6 


Starter lever 


1 




7 


Clutch cable 


1 


Disconnect. 


8 


Clutch lever holder 


1 - 




9 


Right grip end 


1 


Refer to "INSTALLING THE 


10 


Throttle cable 


2 


HANDLEBARS". 


11 


Throttle grip 


1 - 





7-54 



HANDLEBARS 



CHAS 



(£j£ 



'© 



X1 115 Nm (11.5 m«kg, 83 ft»lb) 



13Nm(1.3m«kg, 9.4 ft»lb) 



13Nm(1.3m»kg, 9.4 ft«lb) 



13Nm(1.3nvkg, 9 .4 ft»lb)j 17 

7 




Order 


Job/Part 


Q'ty 


Remarks 


12 


Front brake switch connector 


2 


Disconnect. 


13 


Right handlebar switch 


1 J 




14 
15 


Brake master cylinder holder 
Brake master cylinder 


1 
1 - 


Refer tp "INSTALLING THE 
J HANDLEBARS". 


16 


Handlebar pinch bolt 


2 




17 


Upper bracket bolt 


2 




18 


Upper bracket pinch bolt 


2 




19 


Steering stem nut 


1 




20 


Left handlebar 


1 




21 


Right handlebar 


1 




22 


Upper bracket 


1 


For installation, reverse the removal 
procedure. 



7-55 




HANDLEBARS 



CHAS 



<?fa§ 



REMOVING THE HANDLEBARS 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Remove: 
•grip end 
•handlebar grip 
• left handlebar switch 
•clutch lever holder 



NOTE: 

Blow compressed air between the left handle- 
bar and the handlebar grip, and gradually push 
the grip off the handlebar. 




3. Remove: 
•grip end 

• right handle switch © 
•throttle grip (2) 

• right handlebar switch 
•brake master cylinder holder 



CHECKING THE HANDLEBARS 

1. Check: 
•left handlebar 
• right handlebar 
Bends/cracks/damage — ► Replace. 



A WARNING 



Do not attempt to straighten bent handle- 
bars as this may dangerously weaken them. 



7-56 



Vu t 






^^~fly5sk 






^^ 


rap^\ 


n" x\\ 


.3^ 


A® 





HANDLEBARS 



CHAS 



cafafc 



EAS00674 

INSTALLING THE HANDLEBARS 

1. Install: 
•brake master cylinder holder® 

CAUTION: 



•Install the brake master cylinder holder 

with the "UP" mark facing up. 
• First, tighten the upper bolt, then the lower 

bolt. 



NOTE: 

•Align the mating surfaces of the brake master 
cylinder holder with the punch mark © in the 
right handlebar. 

•There should be 2 mm of clearance between 
the right handlebar switch and the brake mas- 
ter cylinder holder. 




2. Install: 
• right handlebar switch © 
•throttle cables 
•grip end 

NOTE: 



Align the projection (a) on the throttle cable 
housing with the hole® in the right handlebar. 



3. Install: 
•clutch lever holder© 

NOTE: 



Align the slit in the clutch lever holder with the 
punch mark © in the left handlebar. 



7-57 



HANDLEBARS 



CHAS 



ofafc 




4. Install: 
• left handlebar switch © 

NOTE: 



Align the projection (a) on the left handlebar 
switch with the hole (b) in the left handlebar. 



5. Install: 
•handlebar grip 
•grip end 



a. Apply a thin coat of rubber adhesive onto the 
end of the left handlebar. 

b. Slide the handlebar grip over the end of the 
left handlebar. 

c. Wipe off any excess rubber adhesive with a 
clean rag. 



A WARNING 



Do not touch the handlebar grip until the 
rubber adhesive has fully dried. 



Adjust: 

'dutch cable free play 
Refer to "ADJUSTING THE CLUTCH 
CABLE FREE PLAY" in chapter 3. 




Clutch cable free play (at the end 
of the clutch lever) 

10-15 mm (0.39 ~ 0.59 in) 



7. Adjust: 
•throttle cable free play 
Refer to "ADJUSTING THE THROTTLE 
CABLE FREE PLAY" in chapter 3. 




Throttle cable free play (at the 
flange of the throttle grip) 
6-8 mm (0.24 - 0.31 in) 



7-58 



STEERING HEAD 



CHAS 



(2^ 



STEERING HEAD 

LOWER BRACKET 



115 Nm (11.5 nvkg, 83 fHb) 




33 Nm (3.3 nvkg, 
24 fHb) 





^ 


26 Nm (2.6 nvkg, 19 fHb) 




\ 


1st. 


17Nm(1.7m«kg, 12 ft-lb) 


2nd. 


9 Nm (0.9 nvkg, 6.5 fHb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the lower bracket 




Remove the parts in the order listed. 




Front wheel 




Refer to "FRONT WHEEL AND BRAKE 
DISCS". 




Front fork legs 




Refer to "FRONT FORK". 


1 


Main switch coupler 


2 


Disconnect. 


2 


Upper bracket bolt 


2 




3 


Left handlebar assembly 






4 


Right handlebar assembly 






5 


Steering stem nut 






6 


Washer 






7 


Upper bracket 






8 


Lower bracket panel 






9 


Brake hose holder bolt 


2 




10 


Lock washer 






11 


Upper ring nut 




Refer to "CHECK AND ADJUSTING THE 


12 


Rubber washer 




J STEERING HEAD" in chapter 3. 



7-59 



STEERING HEAD 



CHAS 



(2^ 



'© 



X1 13 Nm (1 .3 m»kg, 9.4 ft»lb) 

4 



115 Nm (11.5 m»kg, 83 ft'lb) 




33 Nm (3.3 nvkg, 
24 ft'lb) 





X 


26 Nm (2.6 nvkg, 19 ft-lb) 




\ 


1st. 


17 Nm (1.7 nvkg, 12 ft-lb) 


2nd. 


9 Nm (0.9 nvkg, 6.5 ft«lb) 



Order 


Job/Part 


Q'ty 


Remarks 


13 


Lower ring nut 


1 


Refer to "CHECK AND ADJUSTING THE 
STEERING HEAD" in chapter 3. 


14 


Lower bracket 


1 




15 


Bearing cover 


1 




16 


Bearing inner race 


2 




17 


Upper bearing 


1 




18 


Lower bearing 


1 




19 


Dust seal 


1 




20 


Bearing outer race 


2 


For installation, reverse the removal 
procedure. 



7-60 




STEERING HEAD 



CHAS 



<afa6 



'0 



REMOVING THE LOWER BRACKET 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 

2. Remove: 
•front fork legs 
•steering stem nut 
•upper bracket 
•ring nuts© 
(with the special tool (2)) 




Ring nut wrench 

90890-01403, YU-33975 



A WARNING 



Securely support the lower bracket so that 
there is no danger of it falling. 



CHECKING THE STEERING HEAD 

1. Wash: 
•bearing balls 
• bearing races 



'Y> 



Recommended cleaning solvent 
Kerosine 




2. Check: 
•bearing balls© 
• bearing races (2) 
Damage/pitting -+- Replace. 



3. Replace: 
•bearing balls 
• bearing races 



a. Remove the bearing races from the steering 
head pipe with a long rod © and hammer. 



7-61 




STEERING HEAD 



CHAS 



<£% 



b. Remove the bearing race from the lower 
bracket with a floor chisel (2) and hammer. 

c. Install a new dust seal and new bearing 
races. 

CAUTION: 



If the bearing race is not installed properly, 
the steering head pipe could be damaged. 

NOTE: 

•Always replace the bearing balls and bearing 

races as a set. 
• Whenever the steering head is disassembled, 

replace the dust seal. 



4. Check: 

• upper bracket 

• lower bracket 

(along with the steering stem) 
Bends/cracks/damage -+ Replace. 



INSTALLING THE STEERING HEAD 

1. Lubricate: 

• upper bearing 
•lower bearing 

• bearing races 



Recommended lubricant 
Lithium soap base grease 




Install: 

• bearing 

• bearing cover 
•lower ring nut® 
•rubber washer (2) 
•upper ring nut (3) 
•lock washer® 

Refer to "CHECKING AND ADJUSTING 
THE STEERING HEAD" in chapter 3. 



7-62 



STEERING HEAD 



CHAS 



cfce 



3. Install: 
• upper bracket 
•steering stem nut 

NOTE: 



Temporarily tighten the steering stem nut. 



4. Install: 
•front fork legs 
Refer to "FRONT FORK". 

NOTE: 



Temporarily tighten the upper and lower bracket 
pinch bolts, and handlebar pinch bolts. 



5. Tighten: 
•steering stem nut 



115 Nm (11.5 rtvkg, 83ft«lb) 



■lower bracket pinch bolt 



23 Nm (2.3 trrkg, 17 ft»lb) 



1 upper bracket pinch bolt 



26 Nm (2.6 nvkg, 19 ft»lb) 



■upper bracket bolt 



'handlebar pinch bolt 



13Nm(1.3m»kg, 9.4 ft«lb) 



33 Nm (3.3 trrkg, 24 ft»lb) 



7-63 



REAR SHOCK ABSORBER ASSEMBLY 



CHAS 



<&£ 



REAR SHOCK ABSORBER ASSEMBLY 




40 Nm (4.0 nrkg, 29 fWb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the rear shock absorber 




Remove the parts in the order listed. 




assembly 








Rear wheel 




Refer to "REMOVING THE REAR WHEEL". 


1 


Self-locking nut/bolt 


1/1- 




2 
3 
4 


Self-locking nut/bolt 
Self-locking nut/bolt/coller 
Self-locking nut/bolt 


1/1 

1/1/1 

1/1 


Refer to "REMOVING THE REAR 
SHOCK ABSORBER ASSEMBLY". 


5 


Pin/clip/washer 


1/1/1 




6 


Rear shock absorber assembly 


1 - 




7 


Coller/oil seal/bearing 


1/2/1 




8 


Relay arm 


2 




9 


Coller/oil seal/bearing 


1/2/1 




10 


Connecting arm 


1 




11 


Coller/oil seal/bearing 


1/2/1 


For installation, reverse the removal 
procedure. 



7-64 



REAR SHOCK ABSORBER ASSEMBLY 



CHAS 



efa§ 



HANDLING THE REAR SHOCK ABSORBER 
AND GAS CYLINDER 



A WARNING 



This rear shock absorber and gas cylinder 
contain highly compressed nitrogen gas. 
Before handling the rear shock absorber or 
gas cylinder, read and make sure you under- 
stand the following information. The 
manufacturer cannot be held responsible 
for property damage or personal injury that 
may result from improper handling of the 
rear shock absorber and gas cylinder. 

• Do not tamper or attempt to open the rear 
shock absorber or gas cylinder. 

• Do not subject the rear shock absorber or 
gas cylinder to an open flame or any other 
source of high heat. High heat can cause 
an explosion due to excessive gas pres- 
sure. 

• Do not deform or damage the rear shock 
absorber or gas cylinder in any way. If the 
rear shock absorber, gas cylinder or both 
are damaged, damping performance will 
suffer. 




DISPOSING OF A REAR SHOCK ABSORB- 
ER AND GAS CYLINDER 

Gas pressure must be released before dispos- 
ing of a rear shock absorber and gas cylinder. 
To release the gas pressure, press on the gas 
valve needle with a suitable tool as shown, until 
all of the gas is released (the hissing has 
stopped). 



A WARNING 



Wear eye protection to prevent eye damage 
from released gas or metal chips. 



7-65 



REAR SHOCK ABSORBER ASSEMBLY 



CHAS 



<?fc§ 



REMOVING THE REAR SHOCK ABSORBER 
ASSEMBLY 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



©- 






PV 


==ES 






E^oYo~cY 


^oTo" 


otooTo"~o 


^l 




O^I 


~A£/^ 


T 







gc 



NOTE: 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 

2. Remove: 

• rear wheel 

• rear shock absorber assembly lower bolt © 

• relay-arm-to-swingarm bolt (2) 

NOTE: 

While removing the rear shock absorber as- 
sembly lower bolt, hold the swingarm so that it 
does not drop down. 

3. Remove: 

• rear shock absorber assembly upper bin © 

• rear shock absorber assembly 

NOTE: 

Raise the swingarm and then remove the rear 
shock absorber assembly from between the 
swingarm. 




CHECKING THE REAR SHOCK ABSORBER 
ASSEMBLY AND GAS CYLINDER 

1. Check: 

• rear shock absorber rod 
Bends/damage -+- Replace the rear shock 
absorber assembly. 

• rear shock absorber 

Gas leaks/oil leaks -► Replace the rear 

shock absorber assembly, 
•spring 

Damage/wear — ► Replace the rear shock 

absorber assembly, 
•gas cylinder 

Damage/gas leaks — ► Replace, 
•bushings 

Damage/wear -+ Replace, 
•dust seals 

Damage/wear -f Replace. 

• bolts 
Bends/damage/wear -+ Replace. 



7-66 



REAR SHOCK ABSORBER ASSEMBLY 



CHAS 



0^6 



'© 




CHECKING THE RELAY ARM AND CON- 
NECTING ARM 

1. Check: 

• relay arm © 
•connecting arm (2) 

Damage/wear -► Replace. 

• bearings 
•oil seals 

Damage/pitting ->• Replace, 
•spacers 
Damage/scratches -*■ Replace. 

EAS00698 

INSTALLING THE REAR SHOCK ABSORB- 
ER ASSEMBLY 

1. Lubricate: 

• bearings 
•oil seals 

• spacers 



Recommended lubricant 
Lithium soap base grease 



2. Install: 
•connecting arm 
• relay arm 
•rear shock absorber assembly 

NOTE: 



When installing the rear shock absorber assem- 
bly, lift up the swingarm. 



3. Tighten: 
• connecting-arm-to-frame nut 



40 Nm (4.0 nvkg, 29 ft'lb) 



• relay-arm-to-connecting-arm nut 



> relay-arm-to-swingarm nut 



40 Nm (4.0 nrkg, 29 ft«lb) 



40 Nm (4.0 nrkg, 29 ft»lb) 



> rear shock abs orber assembly lower nut 

| 55 Nm (5.5 m«kg, 40 ft»ibT 



7-67 



SWINGARM AND DRIVE CHAIN 



CHAS 



efcs 



SWINGARM AND DRIVE CHAIN 




6 Nm (0.6 rrvkg, 
4.3 ft-lb) 



Order 


Job/Part 


Q'ty 


Remarks 




Removing the swingarm and drive 




Remove the parts in the order listed. 




chain 








Drive sprocket 




Refer to "ENGINE" in chapter 4. 




Rear wheel 




Refer to "REAR WHEEL, BRAKE DISC, 
AND REAR WHEEL SPROCKET". 




Rear shock absorber assembly 




Refer to "REAR SHOCK ABSORBER 
ASSEMBLY". 


1 


Adjusting bolt/locknut 


2/2 




2 


Drive chain guard 


1 




3 


Rear fender 


1 




4 


Flap 


1 




5 


Pivot shaft nut/washer 


1/1 




6 


Pivot shaft 


1 




7 


Swingarm 


1 





7-68 



SWINGARM AND DRIVE CHAIN 



CHAS 



ofafc 



'© 




6 Nm (0.6 rn-kg, 
4.3 ft'lb) 



Order 



Job/Part 



8 Pivot shaft adjust bolt 

9 Drive chain 

10 Dust cover 

11 Oil seal 

12 Bush 

13 Shim 

14 Drive chain guide 

15 Bush 

16 Left bearing 

17 Right bearing 



Q'ty 



Remarks 



Refer to "REMOVING/INSTALLING THE 
SWINGARM". 



For installation, reverse the removal 
procedure. 



7-69 



SWINGARM AND DRIVE CHAIN 



CHAS 



(£y& 



NOTE: 

Before removing the drive sprocket, drive chain, 
and rear wheel, measure the drive chain slack 
and the length of a tenlink section of the drive 
chain. 



©- 






^3 








(o^oTo oYo c^ 


o 0T0 0Y0 o 


TTwS) 


|JcJ) 


v ®\ 


^ 


~~X^J^ 


/ ^® 



REMOVING THE SWINGARM 

1. Remove: 
•Bolt (connecting rod) © 
•Connecting rod (2) 

NOTE: 



Remove the bolt while holding the swingarm. 




2. Loosen: 
• Pivot shaft adjust bolt © 

NOTE: 



Loosen the pivot shaft adjust bolt using a pivot 
shaft wrench (2) 






Pivot shaft wrench: 

90890-01471, YM-01 471 



3. Remove: 
• Pivot shaft © 
•Swingarm 



EAS00704 

REMOVING THE DRIVE CHAIN 

1. Remove: 
•drive chain 



NOTE: 

When replacing the swingarm, the drive chain is 
cut. 



7-70 



SWINGARM AND DRIVE CHAIN 




CHAS 



0^56 



'© 



EAS00703 

CHECKING THE SWINGARM 

1 . Stand the motorcycle on a level surface. 



A WARNING 



Securely support the motorcycle so that 
there is no danger of it falling over. 



NOTE: - 

Place the motorcycle on a suitable stand so that 
the rear wheel is elevated. 



2. Measure: 
•swingarm side play 
•swingarm vertical movement 

a. Measure the tightening torque of the pivot 
shaft nut. 



V 



\ 



Pivot shaft nut 

95 Nm (9.5 nvkg, 69 fMb) 



Measure the swingarm side play [A] by mov- 
ing the swingarm from side to side. 
If the swingarm side play is out of specifica- 
tion, check the spacers, bearings, washers, 
and dust covers. 



Swingarm side play (at the end 
of the swingarm) 
1.0 mm (0.04 in) 



d. Check the swingarm vertical movement \B\ 

by moving the swingarm up and down. 
If swingarm vertical movement is not smooth or 
if there is binding, check the spacers, bearings, 
washers, and bust covers. 




3. Check: 
•swingarm 
Bends/cracks/damage -+ Replace. 
NOTE: 



If the swingarm must be replaced, the drive 
chain must be cut with a drive chain cutter. 



7-71 



SWINGARM AND DRIVE CHAIN 









c 

1201(170! 


[flM 










4. Check: 
• pivot shaft 
Roll the pivot shaft on a flat surface. 
Bends -+ Replace. 



A WARNING 



Do not attempt to straighten a bent pivot 
shaft. 



5. Wash: 

• pivot shaft 

•pivot shaft adjust bolt 

• dust covers 

• spacer 
•bearings 



<0 



Recommended cleaning solvent 
Kerosine 



6. Check: 
•dust covers 
•spacer 
•oil seals 

Damage/wear - 
•bearings 

Damage/pitting 



Replace. 
+ Replace. 



7-72 



SWINGARM AND DRIVE CHAIN 



© © © ® © © ® ® ® ® © 



n jx^nir ggsgrrn glT n 



iz>watn 



CHAS 



(3^56 



EAS00709 

CHECKING THE DRIVE CHAIN 

1. Measure: 
•ten-link section (a) of the drive chain 
Out of specification -* Replace the drive 
chain. 




Max. ten-link drive chain section 
149 mm (5.87 in) 



NOTE: — . 

•While measuring the ten-link section, push 
down on the drive chain to increase its tension. 

• Measure the length between drive chain roller 
© and© as shown. 

• Perform this measurement at two or three dif- 
ferent places. 





2. Check: 
•drive chain 
Stiffness -+ Clean and lubricate or replace. 



3. Clean: 
•drive chain 



a. Wipe the drive chain with a clean cloth. 

b. Put the drive chain in kerosine and remove 
any remaining dirt. 



7-73 



SWINGARM AND DRIVE CHAIN 




CHAS 



G^g 



'© 



c. Remove the drive chain from the kerosine 
and completely dry it. 

CAUTION: 



This motorcycle has a drive chain with small 
rubber O-rings © between the drive chain 
side plates. Never use high-pressure water 
or air, steam, gasoline, certain solvents 
(e.g., benzine), or a coarse brush to clean 
the drive chain. 

High-pressure methods could force dirt or 
water into the drive chain's internals, and 
solvents will deteriorate the O-rings. A 
coarse brush can also damage the O-rings. 
Therefore, use only kerosine to clean the 
drive chain. 

Don't soak drive drain in kerosine more 
them ten minutes. O-ring is damage by kero- 
sine. 



f — 


— -_i_ 


t ~~ 


— i 


(3) 


1 1 , 1^/ 


■-:■:::::.:.::■: ...A / , 


[ M Am 






(D- 




/ 


/ ,N, J 1 


i 1 t=_ r 


l I 


<. — - 


— - 1 


i -— 


— . > 


12510201 



4. Check: 

• O-rings© 

Damage -+ Replace the drive chain. 

• drive chain rollers (2) 

Damage/wear — ► Replace the drive chain, 
•drive chain side plates® 
Cracks/damage/wear -+ Replace the drive 
chain. 



5. Lubricate: 
•drive chain 



Recommended lubricant 

Engine oil or chain lubricant 
suitable for O-ring chains 




6 Check: 
•drive sprocket 
• rear wheel sprocket 

More than 1 1 A tooth @ wear -»• Replace the 

drive chain sprockets as a set. 

Bent teeth -+ Replace the drive chain 

sprockets as a set. 

® Correct 

© Drive chain roller 

(2) Drive chain sprocket 



7-74 



SWINGARM AND DRIVE CHAIN 



CHAS 



<2^ 



XS> 



INSTALLING THE SWINGARM 

1. Lubricate: 
•bearings 

• spacers 
•dust covers 

• pivot shaft 



Recommended lubricant 
Lithium soap base grease 




2. Install: 
•swingarm 

• pivot shaft 
•washer 

• pivot shaft adju st bolt © 
•pivot shaft nut 

NOTE: 



95 Nm (9.5 nvkg, 69 ft»lb) 



Use the pivot shaft wrench (2) to tighten the piv- 
ot adjust bolt to finger tightness. 




Pivot shaft wrench: 

90890-01471, YM-01 471 



3. Install: 

• rear shock absorber assembly 

•rear wheel 
Refer to "REAR SHOCK ABSORBER AS- 
SEMBLY" and "REAR WHEEL". 

4. Adjust: 

•drive chain slack 
Refer to "ADJUSTING THE DRIVE CHAIN 
SLACK" in chapter 3. 




Drive chain slack 

40 ~ 50 mm (1.5 ~ 1.97 in) 



INSTALLING THE DRIVE CHAIN 

1. Lubricate: 
•drive chain 

2. Install: 
•drive chain 

(with the drive chain riveter) 



7-75 



ELEC 




+ 





CHAPTER 8. 
ELECTRICAL 

ELECTRICAL COMPONENTS 8-1 

INSTRUMENT FUNCTIONS 8-2 

INDICATOR LIGHTS 8-2 

OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT 8-2 

COMBINATION METER 8-3 

SWITCHES 8-5 

CHECKING SWITCH CONTINUITY 8-5 

CHECKING THE SWITCHES 8-6 

CHECKING THE BULBS AND BULB SOCKETS 8-8 

TYPES OF BULBS 8-8 

CHECKING THE CONDITION OF THE BULBS 8-8 

CHECKING THE CONDITION OF THE BULB SOCKETS 8-10 

CHECKING THE LEDs 8-10 

IGNITION SYSTEM 8-11 

CIRCUIT DIAGRAM 8-11 

TROUBLESHOOTING 8-12 

ELECTRIC STARTING SYSTEM 8-16 

CIRCUIT DIAGRAM 8-16 

STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8-17 

TROUBLESHOOTING 8-18 

STARTER MOTOR 8-22 

CHECKING THE STARTER MOTOR 8-24 

ASSEMBLING THE STARTER MOTOR 8-25 

CHARGING SYSTEM 8-26 

CIRCUIT DIAGRAM 8-26 

TROUBLESHOOTING 8-27 

LIGHTING SYSTEM 8-29 

CIRCUIT DIAGRAM 8-29 

TROUBLESHOOTING 8-30 

CHECKING THE LIGHTING SYSTEM 8-31 



ELEC 


_ _ 


+ 





SIGNALING SYSTEM 8-35 

CIRCUIT DIAGRAM 8-35 

TROUBLESHOOTING 8-37 

CHECKING THE SIGNALING SYSTEM 8-38 

COOLING SYSTEM 8-46 

CIRCUIT DIAGRAM 8-46 

TROUBLESHOOTING 8-47 

FUEL PUMP SYSTEM 8-50 

CIRCUIT DIAGRAM 8-50 

FUEL PUMP CIRCUIT OPERATION 8-51 

TROUBLESHOOTING 8-52 

CHECKING THE FUEL PUMP 8-54 

SELF-DIAGNOSIS 8-55 

TROUBLESHOOTING 8-56 



ELECTRICAL COMPONENTS 



ELEC 


— _ 


+ 



ELECTRICAL 



ELECTRICAL COMPONENTS 



Wire harness 

© Main switch 

® Front brake light switch 

Plug top ignition coils 

© Clutch switch 

© Starting circuit cutoff relay 

© Fuse box 

© Flasher relay 

(9) CDI unit 



© Starter relay 

© Main fuse 

© Oil level relay 

© Battery 

© Rectifier/ regulator 

© Rear brake light switch 

© Neutral switch 

© Speed sensor 

© Sidestand switch 

© Stator coil assembly 



© Oil level switch 

© Pickup coil 

© Radiator fan 

©Horn 

© Thermo unit 

© Thermo switch 

© Headlight relay (HI, LO) 




8-1 



INSTRUMENT FUNCTIONS 



ELEC 


_ _ 


+ 





INSTRUMENT FUNCTIONS 

INDICATOR LIGHTS 




© Neutral indicator light "N " 
© High beam indicator light " 10" 
® Turn indicator light "« ■=> " 
© Fuel indicator light " » " 



Turn indicator light 

This indicator flashes when the turn switch is 
moved to the left or right. 

Neutral indicator light "n " 

This indicator comes on when the transmis- 
sion is in neutral. 

High beam indicator light "10" 

This indicator comes on when the headlight 
high beam is used. 

Fuel indicator light "»" 

When the fuel level drops below approxi- 
mately 3.7 L, this light will come on. 
When this light comes on, fill the fuel tank at 
the first opportunity. 



OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT 




© Oil level/coolant temperature warning light" 1 !' 

@ Oil level symbol " t* " 

© Coolant temperature symbol " J~ " 



This warning light has two functions. 

• The light will come on and symbol " ^ " will 
flash if the engine oil level is low. If this sym- 
bol flashes, stop the engine immediately 
and fill it with oil to the specified level. 

•The light will come on and symbol " jl " will 
flash if the coolant temperature is too high. 
The following chart shows the conditions of 
the indicator light, symbol and temperature 
display in accordance with the coolant tem- 
perature. 

CAUTION: 



• Do not run the motorcycle until you know it 
has sufficient engine oil. 

• Do not run the motorcycle if the engine is 
overheated. 



NOTE: 

Even if the oil is filled to the specified level, the 
warning light may flicker when riding on a slope 
or during sudden acceleration or deceleration, 
but this is normal. 



8-2 



INSTRUMENT FUNCTIONS 



ELEC 


— _ 


+ 



Coolant 
temperature 



0°C 
(0°F - 



40°C 
104°F) 



Display 



X 



41°C ~ 117°C 
(106°F ~ 243°F) 



118°C ~ 140°C 
(244°F ~ 284°F) 



141 °C ~ 
(286°F) 



•c 

i n 
l u 



Jo 



Conditions 



Symbol is on and 
"LO" is displayed. 



per 
X 



•c 

q n 
J u 



"Cr. 



IO 



R33T 



_\ ' /_ 












\l/ 



/ I x 



COMBINATION METER 



(2> 



OOi> 
GOO 



■O 



SELECT V 'J 

I r 



o- 



© Speedometer 
© Clock, odometer 
© "SELECT" button 
© "RESET" button 



What to do 



Go ahead with riding. 



Symbol is on and 
temperature is dis- 
played. 



Symbol and tem- 
perature flashes 
and indicator light 
comes on. 



Symbol flashes, 
"HI" is displayed 
and flashes, and 
the indicator light 
comes on. 



Go ahead with riding. 



Stop the motorcycle and 
allow it to idle until the 
coolant temperature goes 
down. 

If the temperature does 
not go down, stop the en- 
gine. Refer to "OVER- 
HEATING" in chapter 9. 



Stop the engine and allow 
it to cool. 

Refer to "OVERHEATING" 
in chapter 9. 




This combination meter is equipped with the fol- 
lowing. 

•A speedometer 
•An odometer 
•Two trip odometers 
•A fuel reserve tripmeter 
•A clock 

To change the speedometer display from kilo- 
meters to miles, press the "SELECT" button for 
at least two seconds. 

Odometer and trip meters 

Use the trip meters to estimate how far you can 
ride on a tank of fuel. 

Use the fuel reserve trip meter to see the dis- 
tance traveled from when the fuel level dropped 
to the reserve level. 



Push the "SELECT" button to change between 
the odometer mode "ODO" and the trip odome- 
ter modes "TRIP 1 "and "TRIP 2" in the following 
order: 
"ODO" -+ "TRIP 1" -► "TRIP 2" -► "ODO" 



8-3 



INSTRUMENT FUNCTIONS 



ELEC 


™ ™ 


+ 





When the fuel level indicator light comes on the 
odometer display will automatically change to 
the fuel reserve trip meter mode "TRIP F" and 
start counting the distance traveled from that 
point. Push the "SELECT" button to change be- 
tween the fuel odometer, trip odometer and 
odometer modes in the following order: 
"TRIP F" -+ "TRIP 1" -f "TRIP 2" -> "ODO" -► 
"TRIP F" 



To reset a trip odometer to 0.0, select it by push- 
ing the "SELECT" button and push the "RESET" 
button for at least one second. To reset the fuel 
reserve trip meter, select it by pushing the "SE- 
LECT" button and push the "RESET" button for 
at least one second. 

The display will return to "TRIP 1". If you do not 
reset the fuel reserve trip meter manually, it will 
automatically reset and return to "TRIP 1" after 
refueling and the motorcycle has traveled both 
5 km and for approximately 3 minutes. 
Clock 

To change the display to the clock mode, push 
both the "SELECT" and "RESET" buttons. 
To set the clock: 

1 . Push both the "SELECT" and "RESET" but- 
tons for at least two seconds. 

2. When the hour digits start flashing, push the 
"RESET" button to set the hours. 

3. Push the "SELECT" button to change the 
minutes. 

4. When the minute digits start flashing, push 
the "RESET" button to set the minutes. 

5. Push the "SELECT" button to start the clock. 

NOTE: 

After setting the clock, be sure to push the "SE- 
LECT" button before turning the main switch to 
"OFF", otherwise the clock will not be set. 



8-4 



SWITCHES 





ELEC 




+ 





SWITCHES 

CHECKING SWITCH CONTINUITY 

Check each switch for continuity with the pocket 
tester. If the continuity reading is incorrect, 
check the wiring connections and if necessary, 
replace the switch. 

CAUTION: 



Never insert the tester probes into the cou- 
pler terminal slots ©. Always insert the 
probes from the opposite end of the coupler, 
taking care not to loosen or damage the 
leads. 




Pocket tester 
90890-03112 



NOTE: _ 

• Before checking for continuity, set the pocket 
tester to "0" and to the "Q x 1" range. 

• When checking for continuity, switch back and 
forth between the switch positions a few times. 

The terminal connections for switches (e.g., 
main switch, engine stop switch) are shown in 
an illustration similar to the one on the left. 
The switch positions are shown in the far left 
column and the switch lead colors are shown in 
the top row in the switch illustration. 

NOTE: 

"O O" indicates a continuity of electricity 

between switch terminals (i.e., a closed circuit 
at the respective switch position). 

The example illustration on the left shows 
that: 

There is continuity between blue/red and red 
when the switch is set to "p£". 
There is continuity between blue/red and blue, 
between brown/blue and red, and between 
blue/yellow and blue/black when the switch is 
set to "ON". 



8-5 



CHECKING THE SWITCHES 



ELEC 


_ _ 


+ 





CHECKING THE SWITCHES 

Check each switch for damage or wear, proper connections, and also for continuity between the termi- 
nals. Refer to "CHECKING SWITCH CONTINUITY". 

Damage/wear -+ Repair or replace the switch. 

Improperly connected -+ Properly connect. 

Incorrect continuity reading -+ Replace the switch. 



® 



oo 



oo 



.A_ 



Br/L 





Ch 


Bf/W 


Dg 


R 




o 


O 


N 








L 


o 


o 







Br 


P 


OFF 






ON 


O 


o 





R/W 


B/R 




[E R/W 


B 






B/W 


L/W 










(6) 


""\^ 


R/W 


3/W 




OFF 








RUN 


OO 






(Z) 


"\^ 


LAV 


e 




FREE 








PUSH 


OO 





8-6 



CHECKING THE SWITCHES 



ELEC 


— — 


+ 





© Main switch 
© Dimmer switch 
© Turn signal switch 
© Horn switch 
© Clutch switch 
© Engine stop switch 



® Start switch 

® Front brake light switch 

© Rear brake light switch 

@> Neutral switch 

©Fuse 

© Sidestand switch 

@> Oil level switch 



8-7 



CHECKING THE BULBS AND BULB SOCKETS 



ELEC 




+ 



CHECKING THE BULBS AND 

BULB SOCKETS 

Check each bulb and bulb socket for damage or 
wear, proper connections, and also for continu- 
ity between the terminals. 
Damage/wear — ► Repair or replace the bulb, 
bulb socket or both. 

improperly connected — ► Properly connect. 
Incorrect continuity reading -+ Repair or re- 
place the bulb, bulb socket or both. 



® 




®s^ 










7? 


^1 


18410603 




TYPES OF BULBS 

The bulbs used on this motorcycle are shown in 
the illustration on the left. 

• Bulbs ® and (B) are used for headlights and 
usually use a bulb holder which must be de- 
tached before removing the bulb. The majority 
of these bulbs can be removed from their re- 
spective socket by turning them counterclock- 
wise. 

• Bulb © is used for turn signal and tail/brake 
lights and can be removed from the socket by 
pushing and turning the bulb counterclock- 
wise. 

• Bulbs® and © are used for meter and indica- 
tor lights and can be removed from their re- 
spective socket by carefully pulling them out. 



CHECKING THE CONDITION OF THE BULBS 

The following procedure applies to all of the 
bulbs. 
1. Remove: 
•bulb 



8-8 



CHECKING THE BULBS AND BULB SOCKETS 



A WARNING 



ELEC 




+ 





Since the headlight butb gets extremely hot, 
keep flammable products and your hands 
away from the bulb until it has cooled down. 

CAUTION: 



• Be sure to hold the socket firmly when re- 
moving the bulb. Never pull the lead, other- 
wise it may be pulled out of the terminal in 
the coupler. 

•Avoid touching the glass part of the head- 
light bulb to keep it free from oil, otherwise 
the transparency of the glass, the life of the 
bulb and the luminous flux will be adverse- 
ly affected. If the headlight bulb gets soiled, 
thoroughly clean it with a cloth moistened 
with alcohol or lacquer thinner. 




Check: 

•bulb (for continuity) 
(with the pocket tester) 
No continuity — ► Replace. 




Pocket tester 
90890-03112 



NOTE: — 

Before checking for continuity, set the pocket 
tester to "0" and to the "ft x 1" range. 



a. Connect the tester positive probe to terminal 
(D and the tester negative probe to terminal 
(3), and check the continuity. 

b. Connect the tester positive probe to terminal 
(2) and the tester negative probe to terminal 
(3), and check the continuity. 

c. If either of the readings indicate no continu- 
ity, replace the bulb. 



8-9 



CHECKING THE BULBS AND BULB SOCKETS 



ELEC 




+ 





CHECKING THE CONDITION OF THE BULB 
SOCKETS 

The following procedure applies to all of the 
bulb sockets. 
1. Check: 
•bulb socket (for continuity) 

(with the pocket tester) 

No continuity — ► Replace. 




Pocket tester 
90890-03112 



NOTE: 

Check each bulb socket for continuity in the 
same manner as described in the bulb section; 
however, note the following. 



0(2) 


© 






P " 



















a. Install a good bulb into the bulb socket. 

b. Connect the pocket tester probes to the re- 
spective leads of the bulb socket. 

c. Check the bulb socket for continuity. 

If any of the readings indicate no continuity, 
replace the bulb socket. 

CHECKING THE LEDs 

The following procedure applies to all of the 

LEDs. 

1. Check: 

LED (for proper operation) 

a. Disconnect the meter assembly coupler 
(meter assembly side). 

b. Connect two jumper leads © from the bat- 
tery terminals to the respective coupler ter- 
minals as shown. 



A WARNING 



•A wire that is used as a jumper lead must 
have at least the same capacity of the bat- 
tery lead, otherwise the jumper lead may 
burn. 

•This check is likely to produce sparks, 
therefore make sure that no flammable gas 
or fluid is in the vicinity. 

c. When the jumper leads are connected to the 
terminals the respective LED should illumi- 
nate. 

Does not light — ► Replace the meter assem- 
bly. 



8-10 



IGNITION SYSTEM 



ELEC 


— _ 


+ 



IGNITION SYSTEM 

CIRCUIT DIAGRAM 




(T) Main switch 
_ (§) Battery 

(6) Main fuse 

(§) Starting circuit cutoff relay 
— (tj) Sidestand switch 

@CDI unit 
■• @ Ignition coil #1 
^ @ Ignition coil #4 

@ Ignition coil #2 

@ Ignition coil #3 

@) Spark plugs 

@ Pickup coil 

@ Neutral switch 

@) Ignition fuse 

@ Engine stop switch 

© Diode 2 



8-11 



IGNITION SYSTEM 



ELEC 




+ 





TROUBLESHOOTING 



The ignition system fails to operate (no 
spark or intermittent spark). 



Check: 

1. main and ignition fuses 

2. battery 

3. spark plugs 

4. ignition spark gap 

5. spark plug cap resistance 

6. ignition coil resistance 

7. pickup coil resistance 

8. main switch 

9. engine stop switch 

10. neutral switch 

11. sidestand switch 

12. starting circuit cutoff relay 

13. wiring 

(of the entire ignition system) 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1) rider seat 

2) fuel tank 

3) air filter case 

4) heat protector plate 

5) front cowling inner panel (right) 

6) side cowling inner panel (right) 

7) side cowling (right) 

• Troubleshoot with the following special tool 
(-s). 



V- 



Ignition checker 
90890-06754 

Pocket tester 
90890-03112 



1 . Main and ignition fuses 



> Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in chap- 
ter 3. 

•Are the main and ignition fuses OK? 







YES 



f 



NO 



Replace the fuse(-s). 



2. Battery 



' Check the condition of the battery. 
Refer to "CHECKING AND CHARGING THE 
BATTERY" in chapter 3. 



H 



Min. open-circuit voltage 
12.8 V or more at 20 C (68 F) 



• Is the battery OK? 







YES 



f 



NO 



> Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Spark plugs 



The following procedure applies to all of the 

spark plugs. 

•Check the condition of the spark plug. 

•Check the spark plug type. 

• Measure the spark plug gap. 

Refer to "CHECKING THE SPARK PLUGS" 

in chapter 3. 




Standard spark plug 

CFMOEK(NGK) 

CR9EK (NGK) (California) 
Spark plug gap 

0.6 ~ 0.7 mm (0.02 ~ 0.03 in) 



• Is the spark plug in good condition, is it of the 
correct type, and its gap within specification? 







YES 



% 



NO 



Re-gap or replace the 
spark plug. 



8-12 



IGNITION SYSTEM 



ELEC 


_ _ 


+ 



4. Ignition spark gap 



The following procedure applies to all of the 
spark plugs. 

• Disconnect the spark plug cap from the spark 
plug. 

•Connect the ignition checker © as shown. 
•©Sparkplug cap 
•Set the main switch to "ON". 
•Measure the ignition spark gap (a). 

• Crank the engine by pushing the start switch 
and gradually increase the spark gap until a 
misfire occurs. 





Min. ignition spark gap 
6 mm (0.24 in) 



> Is there a spark and is the spark gap within 
specification? 



f 



NO 







YES 



The ignition system is 
OK. 



6. Ignition coil resistance 



The following procedure applies to all of the 

ignition coils. 

• Disconnect the ignition coil connectors from 
the ignition coil terminals. 

•Connect the pocket tester (Q, x 1) to the igni- 
tion coil as shown. 



Tester positive probe -+ 

ignition coil terminal 
Tester negative probe -► 

ignition coil terminal 




1 Measure the primary coil resistance. 



m 



Primary coil resistance 

0.238 ~ 0.322 Q. at 20° C (68°F) 



• Connect the pocket tester (Q x 1k) to the 
ignition coil as shown. 

• Measure the secondary coil resistance. 



Tester positive probe -+ 

ignition coil terminal © 
Tester positive probe -+ 

spark plug terminal (2) 





Secondary coil resistance 

8.16 ~ 11.04 kQ at 20°C (68°F) 



Is the ignition coil OK? 







YES 



t 



NO 



Replace the ignition 
coil. 



8-13 



IGNITION SYSTEM 



ELEC 


_ _ 


+ 





7. Pickup coil resistance 



• Disconnect the pickup coil coupler from the 

wire harness. 
•Connect the pocket tester (Q, x 100) to the 

pickup coil terminal. 



Tester positive probe -+ gray © 
Tester negative probe -► black (2) 




■ Measure the pickup coil resistance. 



SJ 



Pickup coil resistance 
248 ~ 372^at20°C(68°F) 
(between gray and black) 



Is the pickup coil OK? 







YES 



* 



NO 



Replace the pickup 
coil. 



8. Main switch 



'Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the main switch OK? 







YES 



# 



NO 



Replace the main 
switch. 



9. Engine stop switch 



•Check the engine stop switch for continuity. 

Refer to "CHECKING THE SWITCHES". 
• Is the engine stop switch OK? 







YES 



f 



NO 



Replace the right 
handlebar switch. 



10. Neutral switch 



' Check the neutral switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the neutral switch OK? 







YES 



f 



NO 



Replace the neutral 
switch. 



11. Sidestand switch 



■ Check the sidestand switch for continuity. 
Refer to "CHECKING THE SWITCHES". 

■ Is the sidestand switch OK? 







YES 



# 



NO 



Replace the side- 
stand switch. 



8-14 



12. Starting circuit cutoff relay 



• Remove the relay unit from the wire harness. 
•Connect the pocket tester (Q x 1) to the relay 

terminals as shown. 

• Check the starting circuit cutoff relay for con- 
tinuity. 



Tester positive probe -► 

sky blue 
Tester negative probe -► 

blue/yellow (§) 



Tester positive probe -► 

blue/yellow (f) 
Tester negative probe -► 

sky blue © 



No 
continuity 



Continuity 



(2) © 















V 






X 




-s/ 



IB Sb L/W 



L/8 L/R L/Y Sb B/Y L B/R 



M 



G _w\ 
L bTrJ 



NOTE: — 

When you switch the "-" and " + " leads of the 
digital pocket tester, the readings in the above 
chart will be reversed. 



' Are the tester readings correct? 







YES 



# 



NO 



Replace the starting 
circuit cutoff relay. 



IGNITION SYSTEM 



ELEC 


™ _ 


+ 



13. Wiring 



•Check the entire ignition system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

> Is the ignition system's wiring properly con- 
nected and without defects? 



f 



NO 



YES 



Properly connect or 
repair the ignition 
system's wiring. 



Replace the ignitor 
unit. 



8-15 



ELECTRIC STARTING SYSTEM 



ELEC 


_ _ 


+ 





ELECTRIC STARTING SYSTEM 

CIRCUIT DIAGRAM 




(T) Main switch 

5) Battery 
© Main fuse 
(7) Starter relay 

?) Starter motor 
&'~ @ Starting circuit cutoff relay 
ji) Sidestand switch 

j) Neutral switch 
@ Clutch switch 
@) Ignition fuse 
@ Engine stop switch 
@) Start switch 
|l) Diode 1 
62) Diode 2 



8-16 



ELECTRIC STARTING SYSTEM 



ELEC 




+ 






STARTING CIRCUIT CUTOFF SYSTEM OP- 
ERATION 

If the engine stop switch is set to "(~) " and the 
main switch is set to "ON" (both switches are 
closed), the starter motor can only operate if at 
least one of the following conditions is met: 

•The transmission is in neutral (the neutral 

switch is closed). 
• The clutch lever is pulled to the handlebar (the 

clutch switch is closed) and the sidestand is up 

(the sidestand switch is closed). 

The starting circuit cutoff relay prevents the 
starter motor from operating when neither of 
these conditions has been met. In this instance, 
the starting circuit cutoff relay is open so current 
cannot reach the starter motor. When at least 
one of the above conditions has been met the 
starting circuit cutoff relay is closed and the en- 
gine can be started by pressing the start switch. 

WHEN THE TRANSMISSION IS IN 

NEUTRAL 

WHEN THE SIDESTAND IS UP AND 

THE CLUTCH LEVER IS PULLED TO 

THE HANDLEBAR 



inn 



Ix x X I 



(D Battery 

(2) Main fuse 

(3) Main switch 

(4) Ignition fuse 

(5) Engine stop switch 

(6) Starting circuit cutoff relay 

(7) Diode 

(8) Clutch switch 

(9) Sidestand switch 
© Neutral switch 
© Start switch 

@ Starter relay 
6$ Starter motor 



8-17 



ELECTRIC STARTING SYSTEM 



ELEC 


_ _ 


+ 





TROUBLESHOOTING 



The starter motor fails to turn. 



Check: 

1 . main and ignition fuses 

2. battery 

3. starter motor 

4. starting circuit cutoff relay 

5. Diode 

6. starter relay 

7. main switch 

8. engine stop switch 

9. neutral switch 

10. sidestand switch 

11. clutch switch 

12. start switch 

13. wiring 

(of the entire starting system) 

NOTE: 



•Before, troubleshooting, remove the following 
part(-s): 

1) rider seat 

2) fuel tank 

3) air filter case 

4) front cowling inner panels 

5) Side cowling inner panels 

6) Side cowlings 

•Troubleshoot with the following special tool 
(-s). 



?> 



Pocket tester 
90890-03112 



1. Main and ignition fuses 



•Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in chap- 
ter 3. 

• Are the main and ignition fuses OK? 







YES 



# 



NO 



Replace the fuse(-s). 



2. Battery 



• Check the condition of the battery. 
Refer to "CHECKING AND CHARGING THE 
BATTERY" in chapter 3. 



m 



Open-circuit voltage 

12.8 V or more at 20°C (68°F) 



• Is the battery OK? 







YES 



# 



NO 



> Clean the battery 

terminals. 
• Recharge or 

replace the battery. 



3. Starter motor 



■ Connect the battery positive terminal © and 
starter motor lead (2) with a jumper lead (3). 




18210801 



A WARNING 



• A wire that is used as a jumper lead must 
have at least the same capacity of the 
battery lead, otherwise the jumper lead 
may burn. 

•This check is likely to produce sparks, 
therefore make sure that no flammable 
gas or fluid is in the vicinity. 

• Does the starter motor turn? 







YES 



f 



NO 



Repair or replace the 
starter motor. 



8-18 



ELECTRIC STARTING SYSTEM 



4. Starting circuit cutoff relay 

• Disconnect the relay from the coupler. 
•Connect the pocket tester (Q. x 1) and bat- 
tery (12 V) to the relay terminals as shown. 



Battery positive terminal 
Battery negative terminal 



red/black 



black/yellow 



Tester positive probe - 
Tester negative probe 



blue/white 
► blue (4) 



ar^t 



V 



® 



^ 



"7 



3 



J 



:/B Sb L/W 



L/B L/R L/Y Sb B/Y L B/R 



B 



g rs 

L B/R~| 



-Does the starting circuit cutoff relay have 
continuity between black and blue/white? 







YES 



# 



NO 



Replace the starting 
circuit cutoff relay 



ELEC 


— _ 


+ 





5. DIODE 



• Disconnect the relay from the coupler. 
•Connect the pocket tester {Cl x 1) to the relay 

terminals as shown. 
■Measure the starting circuit cutoff relay for 

continuity as follows. 



Tester positive probe -+ 

sky blue 
Tester negative probe -+ 

black/yellow (§) 



Tester positive probe -► 

sky blue 
Tester negative probe -► 

blue/yellow (3) 



Tester positive probe -► 

black/yellow (§) 
Tester negative probe -+ 

sky blue 



Tester positive probe -f 

blue/yellow (3) 
Tester negative probe -k 

sky blue 



No 
continuity 



Continuity 



(3)© @ 














*c 






X 




Jr 



i^/B 


Sb 


L/W 






G 


wS 




L/B 


L/R 


L/Y 


Sb 


B/Y 


L 


B/R 



^ 



NOTE: 

When you switch the "-" and " + " leads of the 
digital pocket tester, the readings in the above 
chart will be reversed. 



•Are the tester readings correct? 







YES 



# 



NO 



Replace the starting 
circuit cutoff relay 



8-19 



ELECTRIC STARTING SYSTEM 



ELEC 


— _ 


+ 



6. Starter relay 



• Disconnect the starter relay from the coupler. 

• Connect the pocket tester (Qx1) and bat- 
tery (12 V) to the starter relay coupler as 
shown. 



Battery positive terminal -+ red/white ® 
Battery negative terminal -t- 

blue/white (2) 



Tester positive probe -+- red (D 
Tester negative probe -+ black @ 




^ 




/N 



©i© 



L/W 



R/W 



sxx^ 



•Does the starter relay have continuity be- 
tween red and black? 







YES 



f 



NO 



Replace the starter 
relay. 



7. Main switch 



'Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES" 
'Is the main switch OK? 







YES 



f 



NO 



Replace the main 
switch. 



8. Engine stop switch 



' Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
1 Is the engine stop switch OK? 







YES 



* 



NO 



Replace the right 
handlebar switch. 



9. Neutral switch 



■ Check the neutral switch for continuity. 
Refer to "CHECKING THE SWITCHES". 

■ Is the neutral switch OK? 







YES 



f 



NO 



Replace the neutral 
switch. 



10. Diode 



• Check the diode for continuty. 

• Disconnect the diode from the coupler. 

• Connect the pocket tester (Q x 1 ) to the diode 
terminals as a shown. 

• Measur the diode for continuity as follows. 



Tester positive probe —► 

blue/yellow ® 
Tester negative probe -+ 

blue/black (2) 



Tester positive probe -► 

blue/black (2) 
Tester negative probe -+ 

blue/yellow (T) 



No 
continuity 



Continuity 



L/B 



L/Y 



1 Is the diode ok? 







YES 



# 



NO 



Replace the diode. 



8-20 



ELECTRIC STARTING SYSTEM 



ELEC 




+ 



11. Sidestand switch 



•Check the sidestand switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
• Is the sidestand switch OK? 







YES 



* 



NO 



Replace the 
sidestand switch. 



12. Clutch switch 



•Check the clutch switch for continuity. 
Refer to "CHECKING THE SWITCHES" 
- Is the clutch switch OK? 







YES 



f 



NO 



Replace the clutch 
switch. 



1 3. Start switch 



1 Check the start switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the start switch OK? 







YES 



f 



NO 



Replace the right 
handlebar switch. 



14. Wiring 



•Check the entire starting system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

• Is the starting system's wiring properly con- 
nected and without defects? 



f 



NO 







YES 



Properly connect or 
repair the starting 
system's wiring. 



The starting system 
circuit is OK. 



8-21 



STARTER MOTOR 



ELEC 


_ | 


+ 





STARTER MOTOR 




Order 


Job/Part 


Q'ty 


Remarks 




Removing the starter motor 




Remove the parts in the order listed. 




Rider seat 




Refer to "SEATS" in chapter 3. 




Fuel tank 




Refer to "FUEL TANK" in chapter 3. 




Carburetors 




Refer to "CARBURETORS" in chapter 6. 




Coolant 




Drain 

Refer to "CHANGING THE COOLANT" 

in chapter 3. 




Thermostat 




Refer to "THERMOSTAT" in chapter 5. 


1 


Starter motor lead 


1 




2 


Starter motor assembly 


1 




3 


Throttle stop screw 


1 


For installation, reverse the removal 
procedure. 



8-22 



STARTER MOTOR 



ELEC 




+ 





5 Nm (0.5m»kg, 3.6 ft'lb) 




Order 


Job/Part 


Q'ty 


Remarks 




Disassembling the starter motor 




Remove the parts in the order listed. 


© 


O-ring 






<2> 


Starter motor front cover 






® 


Lock washer 






(4) 


Oil seal 






(5) 


Bearing 






© 


Washer set 









Starter motor rear cover 






® 


Washer set 






® 


O-ring 


2 




@ 


Brush holder set 






© 


O-ring 






© 


Armature assembly 






© 


Starter motor yoke 




For assembly, reverse the disassembly 
procedure. 



8-23 




STARTER MOTOR 



ELEC 


■■ ™ 


+ 





EB803511 

CHECKING THE STARTER MOTOR 

1. Check: 
•commutator 

Dirt -f Clean with 600 grit sandpaper. 

2. Measure: 

• commutator diameter (a) 
Out of specification — ► Replace the starter 
motor. 




Min. commutator diameter 
27 mm (1.06 in) 



3. Measure: 
• mica undercut ® 
Out of specification -+ Scrape the mica to the 
proper measurement with a hacksaw blade 
which has been grounded to fit the commuta- 
tor. 




Mica undercut 
0.7 mm (0.03 in) 



NOTE: 

The mica must be undercut to ensure proper 
operation of the commutator. 




4. Measure: 
•armature assembly resistances (commuta- 
tor and insulation) 

Out of specification —► Replace the starter 
motor. 

a. Measure the armature assembly resis- 
tances with the pocket tester. 



¥> 



Pocket tester 
90890-03112 



m 



Armature assembly 

Commutator resistance © 
0.012 ~ 0.022 Q at 20°C (68°F) 

Insulation resistance (2) 

Above 1 MQ at 20° C (68°F) 



b. If any resistance is out of specification, re- 
place the starter motor. 



8-24 



fe^^ 


18210401 








STARTER MOTOR 



ELEC 




+ 





5. Measure: 
• brush length @ 
Out of specification 
as a set. 



Replace the brushes 




Min. brush length 
3.5 mm (0.14 in) 



6. Measure: 
•brush spring force 
Out of specification 
springs as a set. 



Replace the brush 




Brush spring force 

7.16 ~ 9.52 N (7.16 ~ 9.52 g, 
25.77 ~ 34.27 oz) 



7. Check: 

• gear teeth 
Damage/wear -► Replace the gear. 

8. Check: 



•bearing 
-oil seal 

Damage/wear 

part(-s). 



Replace the defective 




ASSEMBLING THE STARTER MOTOR 

1. Install: 
• brush seat © 

NOTE: 

Align the tab ® on the starter motor rear cover 
with the slot (b) in the yoke. 



2. Install: 

• starter mot or yok e (D 
•0-rings(D|Jgg 
•starter motor front cover 

• starter motor rear cover ' 

• bolts 

NOTE: 



5 Nm (0.5 nvkg, 3.6 ft»lb) 



Align the match marks (a) on the starter motor 
yoke with the match marks © on the front and 
rear covers. 



8-25 



CHARGING SYSTEM 



ELEC 


_ _ 


+ 





CHARGING SYSTEM 

CIRCUIT DIAGRAM 




8-26 



TROUBLESHOOTING 



The battery is not being charged. 



Check: 

1 . main fuse 

2. battery 

3. charging voltage 

4. stator coil assembly resistance 

5. wiring 

(of the entire charging system) 

NOTE: 



CHARGING SYSTEM 



• Before troubleshooting, remove the following 
part(-s): 

1 ) rider seat 

2) fuel tank 

•Troubleshoot with the following special 
tool(-s). 



ELEC 




+ 



2. Battery 



• Check the condition of the battery. 
Refer to "CHECKING AND CHARGING THE 
BATTERY" in chapter 3. 



SH 



Open-circuit voltage 
12.8 V or more at 20°C (68°F) 



■ Is the battery OK? 







YES 



* 



NO 



•Clean the battery 

terminals. 
• Recharge or 

replace the battery. 




Engine tachometer 
90793-80009 

Pocket tester 
90890-03112 



1. Main fuse 



• Check the main fuse for continuity. 

Refer to "CHECKING THE FUSES" in chap- 
ter 3. 

• Is the main fuse OK? 







YES 



* 



NO 



Replace the fuse. 



3. Charging voltage 



'Connect the engine tachometer to the spark 

plug lead of cylinder #1 . 
- Connect the pocket tester (DC 20 V) to the 

battery as shown. 



Tester positive probe -f 

battery positive terminal 
Tester negative probe — ► 

battery negative terminal 



DC 20V 



Q 



©♦ 



! 



+ 



• Start the engine and let it run at approximate- 
ly 5,000 r/min. 

• Measure the charging voltage. 



m 



Charging voltage 
14 Vat 5,000 r/min 



8-27 



CHARGING SYSTEM 



ELEC 




+ 





NOTE: 

Make sure that the battery is fully charged. 

• Is the charging voltage within specification? 



f 



NO 







YES 



The charging circuit 
is OK. 



4. Stator coil assembly resistances 



• Remove the generator cover. 
•Connect the pocket tester (Q x 1) to the sta- 
tor coil assembly coupler as shown. 



Tester positive probe -► white © 
Tester negative probe -+ white (2) 



Tester positive probe -+ white © 
Tester negative probe ->• white (3) 



( 


s- 


-V 


) 

f 


Qx1 

e® ffi 


ffl. 


/ 


v - 




^, 


/ 










V 


1 








V 


V 


v" 


... - . ; 



•Measure the stator coil assembly resis- 
tances. 



SH 



Stator coil resistance 

0.27- 0.33 Q. at 20° C (68°F) 



■ Is the stator coil assembly OK? 







YES 



I 



NO 



Replace the stator 
coil assembly. 



5. Wiring 



'Check the wiring connections of the entire 
charging system. 
Refer to "CIRCUIT DIAGRAM". 

• Is the charging system's wiring properly con- 
nected and without defects? 



f 



NO 







YES 



Properly connect or 
repair the charging 
system's wiring. 



Replace the rectifier/ 
regulator. 



8-28 



LIGHTING SYSTEM 



ELEC 




+ 





LIGHTING SYSTEM 

CIRCUIT DIAGRAM 



(T) Main switch 
(5) Battery 
© Main fuse 
11 /| (P @ Hi 9 n beam indicator light 

;©^-4,;;6i--4>;o> ® Illumination light 
I © 'QIJl © <'Kl @ Dimmer switch 

@ Front turn signal/position light (L) 
@ Front turn signal/position light (R) 
© Headlight 



<£§ Headlight relay (Hi) 
@ Headlight relay (Lo) 
@ Tail/brake light 
@ Headlight fuse 
@) Signaling system fuse 




8-29 



LIGHTING SYSTEM 



ELEC 


_ _ 


+ 





TROUBLESHOOTING 



Any of the following fail to light: head- 
light, high beam indicator light, taillight, 
auxiliary light or meter light. 



Check: 

1 . main, signaling system, and headlight fuses 

2. battery 

3. main switch 

4. dimmer switch 

5. wiring 

(of the entire charging system) 

NOTE: '. 

•Before troubleshooting, remove the following 
part(-s): 

1) seats 

2) fuel tank 

3) air filter case 

4) front cowling inner panels 

5) front cowling 

6) rear cowling 

•Troubleshoot with the following special 
tool(-s). 



y- 



Pocket tester 
90890-03112 



LMain, signaling system, and headlight 
fuses 



•Check the main, signaling system, and 
headlight fuses for continuity. 
Refer to "CHECKING THE FUSES" in chap- 
ter 3. 

'Are the main, signaling system, and head- 
light fuses OK? 







YES 



% 



NO 



Replace the fuse(-s). 



2. Battery 



1 Check the condition of the battery. 
Refer to "CHECKING AND CHARGING THE 
BATTERY" in chapter 3. 



m 



Open-circuit voltage 

12.8 V or more at 20°C (68°F) 



■ Is the battery OK? 







YES 



t 



NO 



•Clean the battery 

terminals. 
• Recharge or 

replace the battery. 



3. Main switch 



•Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
• Is the main switch OK? 







YES 



t 



NO 



Replace the main 
switch. 



8-30 



4. Dimmer switch 



'Check the dimmer switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the dimmer switch OK? 







YES 



t 



NO 



The dimmer switch is 
faulty. Replace the 
left handlebar switch. 



5. Wiring 



■Check the entire lighting system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

1 Is the lighting system's wiring properly con- 
nected and without defects? 







YES 



f 



NO 



Check the condition 
of each of the lighting 
system's circuits. 
Refer to "CHECKING 
THE LIGHTING 

SYSTEM". 



Properly connect or 
repair the lighting 
system's wiring. 



LIGHTING SYSTEM 



ELEC 


H . 


+ 





CHECKING THE LIGHTING SYSTEM 

1 . The headlight and the high beam indicator 
light fail to come on. 



1. Headlight bulb and socket 



• Check the headlight bulb and socket for con- 
tinuity. 

Refer to "CHECKING THE BULBS AND 
BULB SOCKETS". 

'Are the headlight bulb and socket OK? 







YES 



f 



NO 



Replace the head- 
light bulb, socket or 
both. 



2. High beam indicator light LED 



•Check the LED of the high beam indicator 

light. 

Refer to "CHECKING THE LEDs". 
• Is the high beam indicator light LED OK? 







YES 



f 



NO 



Replace the meter 
assembly. 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
headlight and high beam indicator light cou- 
plers as shown. 



(AjWhen the dimmer switch is set to " |0 " 
Q3]When the dimmer switch is set to "10 " 



Headlight 

Tester positive probe — ► 

yellow (T) or green (2) 

Tester negative probe -► black (3) 
High beam indicator light 

Tester positive probe -^yellow (4) 

Tester negative probe -+ black/blue (5) 



8-31 



LIGHTING SYSTEM 



ELEC 


— _ 


+ 





Headlight coupler (wire harness side) 







E 






DC 20V 




V 8 


-©♦ 






<J u 






u 




^ 


i 


)* 



Meter assembly couply (wire harness side) 









-\ 










V 








\ 






-J/ 



L/Y 




G/W 



.A. 



Sb 



3/L 



G/R 



Ch 



R/L 



Dg 



Y/BS 

1J 



• Set the main switch to "ON". 

• Set the dimmer switch to " 10 " or " IO ". 

• Measure the voltage (1 2 V) of yellow (green) 
(2) on the headlight coupler (headlight side). 

• Is the voltage within specification? 







YES 



f 



NO 



The wiring circuit 
from the main switch 
to the headlight cou- 
pler is faulty and must 
be repaired. 



4. Headlight relay (Hi or Lo) 



> Disconnect the headlight relay from the cou- 
pler. 

■Connect the pocket tester (Q x 1) and bat- 
tery (1 2 V) to the headlight relay terminals as 
shown. 



Battery positive terminal -► white/yellow 

(white/green)© 
Battery negative terminal -► black (2) 



Tester positive probe -+ 

yellow (green) 
Tester negative probe -+ red/yellow (3) 




>> 



W/Y 

iW/GU 



M 



R/Y 



SSS^ 



» Does the headlight relay have continuity be- 
tween yellow (green) and red/yellow? 







YES 



# 



NO 



This circuit is OK. 



Replace the head- 
light relay. 



2. Illumination fails to come on. 



1. Meter light bulb and socket. 



•Check the meter light bulb and socket for 

continuity. 

Refer to "CHECKING THE BULBS AND 

BULB SOCKETS". 
•Are the meter light bulb and socket OK? 







YES 



t 



NO 



Replace the meter 
light bulb, socket or 
both. 



2. Voltage 



> Connect the pocket tester (20 V) to the meter 
assembly coupler (wire harness side) as 
shown. 



Tester positive probe -+ blue (T) 
Tester negative probe -> black/blue (2) 



<P 































V- 












-S 



R - L/Y W B/L G/R R/L Y/Ef 



[ Br |G/W 



.A. 



Sb Y Ch Dg L 

~rT 



8-32 



» Set the main switch to "ON". 
» Measure the voltage (1 2 V) of blue © on the 
meter assembly coupler (wire harness side). 
• Is the voltage within specification? 







YES 



f 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the meter assem- 
bly coupler is faulty 
and must be re- 
paired. 



LIGHTING SYSTEM 



ELEC 


— _ 


+ 





> Set the main switch to "ON". 

• Measure the voltage (12 V) of blue/red ©on 
the tail/brake light coupler (wire harness 
side). 

• Is the voltage within specification? 







YES 



f 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the tail/brake light 
coupler is faulty and 
must be repaired. 



3. A tail/brake light fails to come on. 



1. Tail/brake light bulb and socket 



> Check the tail/brake light bulb and socket for 

continuity. 

Refer to "CHECKING THE BULBS AND 

BULB SOCKETS". 
■Are the tail/brake light bulb and socket OK? 







YES 



# 



NO 



Replace the tail/ 
brake light bulb, sock- 
et or both. 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
tail/brake light coupler (wire harness side) as 
shown. 



Tester positive probe -> blue/ red © 
Tester negative probe -+ black (5) 



Q 





JoL 



B 



L/R 



® 



4. The turn signal/position light fails to come 
on. 



1. Turn signal/position light bulb and socket 



•Check the turn signal/position light bulb and 

socket for continuity. 

Refer to "CHECKING THE BULBS AND 

BULB SOCKETS". 
►Are the turn signal/position light bulb and 

socket OK? 







YES 



t 



NO 



Replace the turn sig- 
nal/position light bulb, 
socket or both. 



2. Voltage 



•Connect the pocket tester (DC 20 V) to the 
turn signal/position light couplers (wire har- 
ness side) as shown. 



Tester positive probe -> blue © 
Tester negative probe -t- black (2) 




8-33 



LIGHTING SYSTEM 



ELEC 


_ _ 


- + 





• Set the main switch to "ON". 

• Measure the voltage (1 2 V) of blue © on the 
turn signal/position light couplers (wire har- 
ness side). 

• Is the voltage within specification? 







YES 



# 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the turn signal/posi- 
tion light connectors 
is faulty and must be 
repaired. 



8-34 



SIGNALING SYSTEM 



ELEC 




+ 



SIGNALING SYSTEM 

CIRCUIT DIAGRAM 




8-35 



SIGNALING SYSTEM 



ELEC 


— „. 


+ 





Main switch 

© Battery 

© Main fuse 

@ Starting circuit cutoff relay 

© Fuel sender 

@ Neutral switch 

@ Speed sensor 

@) Fuel level indicator light 

@ Oil level/coolant temperature 

warning light 
@ Neutral indicator light 
@) Tachometer 
@ Combination meter 
@ Turn signal indicator light 
@) Horn switch 
@ Horn 

@) Turn signal switch 
@) Flasher relay 

@ Front turn signal/position light (L) 
@ Front turn signal/position light (R) 
@ Rear turn signal light (L) 
© Rear turn signal light (R) 
© Tail/brake light 
@) Signaling system fuse 
@) Oil level relay 
@) Oil level switch 
@ Rear brake light switch 
@) Front brake light switch 



8-36 



SIGNALING SYSTEM 



TROUBLESHOOTING 



• Any of the following fail to light: turn sig- 
nal light, brake light or an indicator light. 
•The horn fails to sound. 



Check: 

1 . main and signaling system fuses 

2. battery 

3. main switch 

4. wiring 

(of the entire signaling system) 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1) seats 

2) fuel tank 

3) air filter case 

4) front cowling inner panels 

5) bottom cowling 

6) side cowling inner panels 

7) side cowlings 

8) windshield 

9) rear cowling 

•Troubleshoot with the following special tool 
(-s). 




Pocket tester 
90890-03112 



ELEC 


— _ 


+ 



2. Battery 



•Check the condition of the battery. 
Refer to "CHECKING THE BATTERY" in 
chapter 3. 



H# 



Open-circuit voltage 

12.8 V or more at 20°C (68°F) 



■ Is the battery OK? 







YES 



f 



NO 



•Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



'Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
' Is the main switch OK? 







YES 



* 



NO 



Replace the main 
switch. 



1 . Main and signaling system fuses 



• Check the main and signaling system fuses 
for continuity. 

Refer to "CHECKING AND CHARGING 
THE FUSES" in chapter 3. 
'Are the main and signaling system fuses 
OK? 







YES 



t 



NO 



Replace the fuse(-s). 



4. Wiring 



•Check the entire signaling system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

• Is the signaling system's wiring properly con- 
nected and without defects? 







YES 



# 



NO 



Check the condition 
of each of the signal- 
ing system's circuits. 
Refer to "CHECKING 
THE SIGNALING 
SYSTEM". 



Properly connect or 
repair the signaling 
system's wiring. 



8-37 



SIGNALING SYSTEM 



ELEC 


_ • 


+ 





CHECKING THE SIGNALING SYSTEM 

1 . The horn fails to sound. 



1 . Horn switch 



•Check the horn switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
• Is the horn switch OK? 







YES 



# 



NO 



Replace the left han- 
dlebar switch. 



2. Voltage 



> Connect the pocket tester (DC 20 V) to the 
horn connector at the horn terminal as 
shown. 



Tester positive probe -t- pink © 
Tester negative probe -+ ground 




■Set the main switch to "ON". 

■ Push the horn switch. 

■ Measure the voltage (12 V) of pink © at the 
horn terminal. 

■ Is the voltage within specification? 







YES 



* 



NO 



The wiring circuit 
from the main switch 
to the horn connector 
is faulty and must be 
repaired. 



3. Horn 



• Disconnect the black connector at the horn 
terminal. 

• Connect a jumper lead © to the horn terminal 
and ground the jumper lead. 

•Set the main switch to "ON". 

• Push the horn switch. 

• Does the horn sound? 




4. Voltage 



• Connect the pocket tester (DC 20 V) to the 
horn connector at the black terminal as 
shown. 



Tester positive probe -► black © 
Tester negative probe -+ ground 




• Set the main switch to "ON". 

• Measure the voltage (1 2 V) of brown © at the 
horn terminal. 

• Is the voltage within specification? 







YES 



f 



NO 



Repair or adjust the 
horn. 



Replace the horn. 



8-38 



SIGNALING SYSTEM 



2. A tail/brake light fails to come on. 



1 . Tail/brake light bulb and socket 



• Check the tail/brake light bulb and socket for 

continuity. 

Refer to "CHECKING THE BULBS AND 

BULB SOCKETS". 
-Are the tail/brake light bulb and socket OK? 







YES 



# 



NO 



Replace the tail/ 
brake light bulb, sock- 
et or both. 



ELEC 




+ 



•Set the main switch to "ON". 

• Pull in the brake lever or push down on the 
brake pedal. 

•Measure the voltage (12 V) of yellow at the 
tail/brake light coupler (wire harness side). 

• Is the voltage within specification? 







YES 



This circuit is OK. 



f 



NO 



The wiring circuit 
from the main switch 
to the tail/brake light 
coupler is faulty and 
must be repaired. 



2. Brake light switches 



1 Check the brake light switches for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the brake light switch OK? 







YES 



# 



NO 



Replace the brake 
light switch. 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
tail/brake light coupler (wire harness side) as 
shown. 



Tester positive probe -t- yellow © 
Tester negative probe -+ black (2) 



Q) 





L Y 



J5L 



Y L/R 



77777^ 



© 



3. A turn signal light, turn signal indicator light 
or both fail to blink. 



1 . Turn signal light bulb and socket 



> Check the turn signal light bulb and socket for 

continuity. 

Refer to "CHECKING THE BULBS AND 

BULB SOCKETS". 
•Are the turn signal light bulb and socket OK? 







YES 



* 



NO 



Replace the turn sig- 
nal light bulb, socket 
or both. 



2. Turn signal indicator light LED 



•Check the LED of the turn signal indicator 

light. 

Refer to "CHECKING THE LEDs". 
' Is the turn signal indicator light LED OK? 







YES 



f 



NO 



Replace the meter 
assembly. 



8-39 



SIGNALING SYSTEM 



ELEC 




+ 





3. Turn signal switch 



•Check the turn signal switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
• Is the turn signal switch OK? 







YES 



f 



NO 



Replace the left han- 
dlebar switch. 



4. Voltage 



•Connect the pocket tester (DC 20 V) to the 
relay coupler (wire harness side) as shown. 



Tester positive probe -»• brown © 
Tester negative probe -+ ground 



n ji 



n n 



C Br/W 



Br 



xxxx^ 



-© 



• Set the main switch to "ON". 

• Measure the voltage (1 2 V) of brown © at the 
turn signal relay coupler (wire harness side). 

• Is the voltage within specification? 







YES 



# 



NO 



The wiring circuit 
from the main switch 
to the turn signal relay 
coupler (turn signal 
relay side) is faulty 
and must be repaired. 



5. Voltage 



•Connect the pocket tester (DC 20 V) to the 
turn signal relay coupler (wire harness side) 
as shown. 



Tester positive probe -+■ brown/white © 
Tester negative probe — ► ground 












i 






p n 


IE 


S/^. 


Br/W 


v\\\y 


Br 






1 










• Set the main switch to "ON". 

• Set the turn signal switch to " <p " or " O ". 

• Measure the voltage (1 2 V) or brown /white at 
the turn signal relay coupler (wire harness 
side). 

• Is the voltage within specification? 







YES 



# 



NO 



The turn signal relay 
is faulty and must be 
replaced. 



6. Voltage 



•Connect the pocket tester (DC 20 V) to the 
turn signal light connectors or the meter as- 
sembly coupler (wire harness side) as 
shown. 



[A] Turn signal light 
[B]Turn signal indicator light 



Left turn signal light 
Tester positive probe - 
Tester negative probe 

Right turn signal light 
Tester positive probe - 
Tester negative probe 



chocolate © 

► ground 

dark green (§) 

► ground 



A 



Ch Dg 



©" 



AS 



B 





1 




| 










^t 




[ 








P 


A 


/r_ 


— 


L/Y 


W 


B/L 


G.'R 


R/L 


W| 


Br 


G/W 


- 


Sb 


V 


■ Ch 


Dg 


I 



H 



8-40 



SIGNALING SYSTEM 



ELEC 




+ 



• Set the main switch to "ON". 

• Set the turn signal switch to " <p " or " ^> ". 

• Measure the voltage (1 2 V) of chocolate © or 
dark green© at the turn signal light connec- 
tor (wire harness side). 

• Is the voltage within specification? 







YES 



I 



NO 



This circuit is OK. 



The wiring circuit 
from the turn signal 
switch to the turn sig- 
nal light connector is 
faulty and must be re- 
paired. 



4. The neutral indicator light fails to come on. 



1 . Neutral indicator light LED 



•Check the LED of the neutral indicator light. 

Refer to "CHECKING THE LEDs". 
• Is the neutral indicator light LED OK? 







YES 



t 



NO 



Replace the meter 
assembly. 



2. Neutral switch 



'Check the neutral switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
■ Is the neutral switch OK? 







YES 



t 



NO 



Replace the neutral 
switch. 



3. Voltage 



•Connect the pocket tester (DC 20 V) to the 
meter assembly coupler (wire harness side) 
as shown. 



Tester positive probe -+ brown © 
Tester negative probe -+- sky blue ( 



^ 



J 




•Set the main switch to "ON". 

• Measure the voltage (1 2 V) of brown © and 
sky blue (2) at the meter assembly coupler. 

• Is the voltage within specification? 







YES 



f 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the meter light bulb 
coupler is faulty and 
must be repaired. 



5. The oil level warning light fails to come on. 



1 . Oil level warning light LED 



■Check the LED of the oil level warning light. 
Refer to "CHECKING THE LEDs". 
■ Is the oil level warning light LED OK? 







YES 



% 



NO 



Replace the meter 
assembly. 



8-41 



SIGNALING SYSTEM 



ELEC 


_ _ 


+ 





2. Oil level switch 



• Drain the engine oil and remove the oil level 
switch from the oil pan. 

•Check the oil level switch for continuity. 
Refer to "CHECKING THE SWITCHES". 

• Is the oil level switch OK? 







YES 



f 



NO 



Replace the oil level 
switch. 



3. Oil level relay 



> Disconnect the oil level relay from the cou- 
pler. 

> Connect the pocket tester (Q x 1 ) and bat- 
tery (12 V) to the oil level relay terminals as 
shown. 



Battery positive terminal -+- brown © 
Battery negative terminal -+ white (§) 



Tester positive probe -► red/blue 
Tester negative probe -*■ black (4) 




-^- 



w 



Br 



R/L 



£S^ 



• Does the oil level relay have continuity be- 
tween red/blue and black? 







YES 



t 



NO 



Replace the oil level 
relay. 



4. Voltage 



■Connect the pocket tester (DC 20 V) to the 
meter assembly coupler (wire harness side) 
as shown. 



Tester positive probe -► brown (T) 
Tester negative probe -+ red/blue 



























c 














A 




A _-J 


£) 


£ 


— 


L/Y 


W 


B/L 


G/R 


R/L 


Y/ih 




it 


G/W 


— 


Sb 


Y 


Ch 


Dg 


L 





1 



Set the main switch to "ON". 
' Measure the voltage (12 V) of brown (T) and 
red/blue at the meter assembly coupler. 
1 Is the voltage within specification? 







YES 



# 



NO 



This circuit is OK. 



The wiring circuit 
from the main switch 
to the meter assem- 
bly coupler is faulty 
and must be re- 
paired. 



6. The fuel level indicator light fails to come 
on. 



1 . Fuel level indicator light LED 



■ Check the LED of the fuel level indicator light. 
Refer to "CHECKING THE LEDs". 

■ Is the fuel level indicator light LED OK? 







YES 



f 



NO 



Replace the meter 
assembly. 



8-42 



SIGNALING SYSTEM 



2. Fuel sender 



• Disconnect the fuel sender coupler from the 
wire harness. 

• Drain the fuel from the fuel tank and remove 
the fuel sender from the fuel tank. 

•Check the fuel sender for continuity. 



Tester positive probe -+ green © 
Tester negative probe -+ black (2) 




1 Is the fuel sender OK? 







YES 



f 



NO 



Replace the fuel 
sender. 



3. Voltage 



Connect the pocket tester (DC 20 V) to the me- 
ter assembly coupler (wire harness side) as 
shown. 



Tester positive probe - 
Tester negative probe 



green/white © 
► black/blue (2) 























^C 














-)/ 




L/Y W 



G/W, — Sb 



.A. 



B/L G/R R/L Y/B 



M 



Ch Dg L 



ELEC 


_ — 


+ 



8-43 



•Set the main switch to "ON". 
•Measure the voltage (12 V). 
• Is the voltage within specification? 







YES 



f 



NO 



This circuit OK. 


The wiring circuit from 
the main switch to the 
meter assembly cou- 
pler is faulty and must 
be repaired. 





EAS00805 

7. The clock fails to come on. 



1 . Voltage 



Connect the pocket tester (20 V DC) to the 
clock coupler (clock side) as shown. 



Tester positive probe -► brown © 
Tester negative probe -+ ground 



















V- 














^y) 









A 








(* 


— 


L/Y 


w 


B/L 


G/R 


R/L 


y/bN 


Br 


G/W 


— 


Sb 


Y 


Ch 


Dg 


A 








K 









(D 



Set the main switch to "ON". 
Measure the voltage (12 V). 
Is the voltage within specification? 







YES 



# 



NO 



The wiring circuit from the main 
switch to the clock coupler 
(clock side) is faulty and must be 
repaired. 



2. Clock 



Check that the clock is operating properly. 
When setting the clock after its power source 
has been disconnected (e.g., when the battery 
is removed), first set the clock to 1 :00 AM and 
then to the correct time. 
Is the clock operating properly? 







YES 



# 



NO 



This circuit is OK. 



Replace the 



SIGNALING SYSTEM 



ELEC 


m i 


+ 





8. The speedometer fails to come on. 



1 . Speedometer bulb socket 



• Check the speedometer bulb socket for con- 
tinuity. 

• Is the speedometer bulb socket OK? 







YES 



t 



NO 



Replace the speedometer bulb 
socket. 



2. Voltage 



• Connect the pocket tester (20 V DC) to the 
speedometer coupler (wire harness side) as 
shown. 



Battery positive lead - 
Battery negative lead 
Battery positive lead - 



green/yellow © 
► black/blue (2) 
red (3) 




^ 






A 








f R 


— 


L/Y 


w 


B/L 


G/R 


R/L 


y/bN 


K 


G/W 


— 


Sb 


Y 


Ct) 


Dg 


L 


(U 






J 


• 









GOO 



i 000 po oooo, 
ijrap oooooo; 



SELECT 



o o 



RESET 



-CLOCK- 




SELECT 



o] lo 



i> RESET 



NOTE: 

First, connect the battery to the brown © and 
black/blue(2) coupler terminals, then connect 
the battery positive lead to the red (3) termi- 
nal. 

When connecting the battery, check whether 
the startup display (4) appears first and then 
after approximately three seconds the normal 
display appears (5) . 



Does the startup display appear first and then 
after approximately three seconds the normal 
display appears? 







YES 



I 



NO 



Replace the speedometer. 



3. Voltage 



-Connect the pocket tester (20 V DC) to the 
speedometer bulb socket coupler (wire har- 
ness side) as shown. 



Tester positive probe - 
Tester negative probe 



blue © 
>■ black/blue 



















V 














-J 




L/Y W 



.A 



B/L G/R R/L Y/B 



Sb Y Ch 



"1 



5 



•Set the main switch to "ON". 

- Measure the voltage (12 V) of blue© on the 
speedometer bulb socket coupler (wire har- 
ness side). 

• Is the voltage within specification? 







YES 



f 



NO 



The wiring circuit from the main 
switch to the speedometer bulb 
socket coupler (wire harness 
side) is faulty, repair it. 



8-44 



SIGNALING SYSTEM 



ELEC 


— _ 


+ 





4. Speedometer sensor 



•Connect the pocket tester (20 V DC) to the 
speedometer coupler (wire harness side) as 
shown. 



Tester positive probe 
Tester negative probe 



blue/yellow ® 

► black/blue (2) 



^ 



e 



R — L/Y W B/L G/R R/L Y/B 



Br G/W — Sb 



A. 



"¥ 



Ch Dg 



6 



• Set the main switch to "ON". 

• Elevate the rear wheel and slowly rotate it. 

- Measure the voltage (5 V) of blue/yellow and 
black/blue. With each full rotation of the rear 
wheel, the voltage reading should cycle from 
V to 5 V to V to 5 V. 

• Does the voltage reading cycle correctly? 







YES 



f 



NO 



This circuit is OK. 


Replace the speedom- 
eter sensor. 





8-45 



COOLING SYSTEM 



ELEC 


_ _ 


+ 





COOLING SYSTEM 

CIRCUIT DIAGRAM 



(7) Main switch 

© Battery 

© Main fuse Jpji Jpji 

&i Thermo unit S.JpL.., 

@ Oil level /coolant temperature ^JT^ !!n=f@ ! 

warning light ^_ 
@) Combination meter 

@ Radiator fan motor — 
@> Thermo switch .-~BHE 

@) Radiator fan motor fuse ji . , 

@ Signaling system fuse ^° 









®>16> Efa 




8-46 



COOLING SYSTEM 



ELEC 




+ 





TROUBLESHOOTING 



•The radiator fan motor fails to turn. 
•The coolant temperature display and/or 

warning light fails to indicate when the 

engine is warm. 



Check: 

1 . main, signal system, and radiator fan motor 
fuses 

2. battery 

3. main switch 

4. radiator fan motor 

5. thermo switch 

6. thermo unit 

7. wiring 

(the entire cooling system) 

NOTE: 

•Before troubleshooting, remove the following 
part(-s): 

1 ) rider seat 

2) bottom cowling 

3) front cowling inner panels 

4) side cowling inner panels 

5) side cowlings 

6) windshield 

•Troubleshoot with the following special tool 
(-s). 



y- 



Pocket tester 
90890-03112 



LMain, signal system and radiator fan 
motor fuses 



•Check the main, signal system, and radiator 
fan motor fuses for continuity. 
Referto "CHECKING THE FUSES" in chap- 
ter 3. 

1 Are the main, signal system, and radiatorfan 
motor fuses OK? 







YES 



f 



NO 



Replace the fuse(-s). 



2. Battery 



• Check the condition of the battery. 
Refer to "CHECKING AND CHARGING 
THE BATTERY" in chapter 3. 



@4 



Open-circuit voltage 

12.8 V or more at 20°C (68°F) 



Is the battery OK? 







YES 



# 



NO 



• Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



•Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
1 Is the main switch OK? 







YES 



t 



NO 



Replace the main 
switch. 



4. Radiator fan motor (test 1 ; 



•Disconnect the radiator fan motor coupler 
from the wire harness. 
•Connect the battery (12 V) as shown. 



Battery positive lead -+ blue © 
Battery negative lead -► black (§) 




■ Does the radiator fan motor turn? 







YES 



t 



NO 



The radiator fan mo- 
tor is faulty and must 
be replaced. 



8-47 



COOLING SYSTEM 



ELEC 


_ _ 


+ 



5. Radiator fan motor (test 2) 



> Disconnect the thermo switch coupler. 
-Set the main switch to "ON". 
-Connect the brown ® and blue (2) terminals 
with a jumper lead (3) as shown. 




» Does the radiator fan motor turn? 







YES 



f 



NO 



The wiring circuit 
from the main switch 
to the radiator fan mo- 
tor coupler is faulty 
and must be repaired. 



6. Thermo switch 



• Remove the thermo switch from the radiator. 

•Connect the pocket tester {Q. x 1) to the ther- 
mo switch (T)as shown. 

•Immerse the thermo switch in a container 
filled with coolant (2). 

NOTE: 



Make sure that the thermo switch terminals 
do not get wet. 



• Place a thermometer (3) in the coolant. 

> Slowly heat the coolant, then let it cool to the 
specified temperature as indicated in the 
table. 

> Check the thermo switch for continuity at the 
temperatures indicated in the table. 



Test 
step 



1 



Coolant temperature 



Thermo switch 



~ 105±3°C 
(0 ~ 221 ± 5.4°F) 



More than 105±3°C 
(221 ± 5.4°F) 



105±3°Cto100±3°C 

(221 ±5.4°Fto212± 

5.4°F) 



Less than 100±3°C 
(212±5.4°F) 



Continuity 



NO 



YES 



YES 



NO 



Test steps 1 & 2: Heating phase 
Test steps 3* & 4*: Cooling phase 




6 b b (5 b 6 



A WARNING 



•Handle the thermo switch with special 

care. 
•Never subject the thermo switch to 

strong shocks. If the thermo switch is 

dropped, replace it. 



\ 



K 



Thermo switch 

28 Nm (2.8 m«kg, 20 ft-lb) 
Three bond sealock® 10 



[A] The thermo switch circuit is open and the ra- 
diator fan is off. 

ID The thermo switch circuit is closed and the 
radiator fan is on. 



8-48 






&. 



m 



v 



100 + 3 °C 
(212±5.4°F) 



105±3°C 
(221 ± 5.4°F) 



> Does the thermo switch operate properly as 
described above? 







YES 



f 



NO 



Replace the thermo 
switch. 



7. Thermo unit 



•Remove the temperature sender from the 

cylinder head. 
•Connect the pocket tester (Q, x 10) to the 

thermo unit (T) as shown. 

• Immerse the thermo unit in a container filled 
with coolant (2). 

• Place a thermometer® in the coolant. 

• Slowly heat the water, then let it cool down to 
the specified temperature. 

•Check the thermo unit for continuity at the 
temperatures indicated below. 



□ii 



Thermo unit resistance 

50.6 ~ 64.2 Q at 80° C (176°F) 
17.3 ~ 16.1 Qat120°C(248°F) 



COOLING SYSTEM 



ELEC 


— _ 


+ 






-® 




O ^x O 

+ 



€ 



o^n^ 



-^jj 




6 b 6 t) 6 



A WARNING 



Handle the temperature sender with spe- 
cial care. 

Never subject the temperature sender to 
strong shocks. If the temperature sender 
is dropped, replace it. 



^ 



Temperature sender 

15Nm(1.5m-kg, 11 fMb) 
Three bond sealock® 10 







YES 



f 



NO 



Replace the tempera- 
ture sender. 



8. Wiring 



'Check the entire cooling system's wiring. 
Refer to "CIRCUIT DIAGRAM". 

■Is the cooling system's wiring properly con- 
nected and without defects? 







YES 



f 



NO 



Replace the com- 
bination meter. 



Properly connect or 
repair the cooling 
system's wiring. 



8-49 



FUEL PUMP SYSTEM 



ELEC 




+ 





FUEL PUMP SYSTEM 

CIRCUIT DIAGRAM 



;<5 p^;[<5 p *;sp4.;;@p-Hir; 




_ Main switch 



5) Battery 



"^'^jilfj © ©Main fuse 



@ Starting circuit cutoff relay 

@i Fuel pump 

^CDI unit 

@ Ignition fuse 

H> Engine stop switch 



8-50 



FUEL PUMP SYSTEM 



ELEC 




+ 





FUEL PUMP CIRCUIT OPERATION 

The CDI unit includes the control unit for the fuel pump. 

Battery 

© Main fuse 

© Main switch 

(4) Ignition fuse 

© Engine stop switch 

©CDI unit 

© Starting circuit cutoff relay 

@ Fuel pump 




8-51 



FUEL PUMP SYSTEM 



ELEC 


- , 


+ 



TROUBLESHOOTING 



The fuel pump fails to operate. 



Check: 

1. main and ignition fuses 

2. battery 

3. main switch 

4. engine stop switch 

5. starting circuit cutoff relay 

6. fuel pump 

7. wiring 

(the entire fuel pump system) 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1 ) rider seat 

2) fuel tank 

3) air filter case 

4) front cowling inner panel (left) 
•Troubleshoot with the following special 

tool(-s). 




Pocket tester 
90890-03112 



1. Main and ignition fuses 



• Check the main and ignition fuses for conti- 
nuity. 

Refer to "CHECKING THE FUSES" in chap- 
ter 3. 

• Are the main and ignition fuses OK? 







YES 



f 



NO 



Replace the fuse(-s). 



2. Battery 



■Check the condition of the battery. 
Refer to "CHECKING AND CHARGING THE 
BATTERY" in chapter 3. 



m 



Open-circuit voltage 

12.8 V or more at 20° C (68°F) 



■ Is the battery OK? 







YES 



* 



NO 



• Clean the battery 
terminals. 

• Recharge or re- 
place the battery. 



3. Main switch 



1 Check the main switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
' Is the main switch OK? 







YES 



# 



NO 



Replace the main 
switch. 



4. Engine stop switch 



•Check the engine stop switch for continuity. 
Refer to "CHECKING THE SWITCHES". 
' Is the engine stop switch OK? 







YES 



# 



NO 



Replace the right 
handlebar switch. 



8-52 



FUEL PUMP SYSTEM 



ELEC 


_ _ 


+ 





5. Starting circuit cutoff relay 



• Disconnect the relay from the coupler. 

• Connect the pocket tester (Q x 1 ) and bat- 
tery (12 V) to the relay terminals as shown. 



Battery positive terminal 
Battery negative terminal 



red /black © 

► blue/red (2) 



Tester positive probe 
Tester negative probe 



red/black © 
► blue/black (3 



or* 



E^ 



# 






[l/B 



Sb 



L/R 



L/W 



L/Y 



B/Y 



G WS 



• Does the fuel pump relay have continuity be- 
tween red/black and blue/black? 







YES 



t 



NO 



Replace the starting 
circuit cutoff relay. 



'Measure the fuel pump resistance. 



m 



Fuel pump resistance 
4 - 30Qat20 o C(68°F) 



■Is the fuel pump OK? 







YES 



f 



NO 



Replace the 
pump. 



fuel 



7. Wiring 



•Check the entire fuel pump system's wiring. 

Refer to "CIRCUIT DIAGRAM". 
•Is the fuel pump system's wiring properly 

connected and without defects? 







YES 



f 



NO 



Replace the CDI unit. 



Properly connect or 
repair the fuel pump 
system's wiring. 



6. Fuel pump resistance 



• Disconnect the fuel pump coupler from the 
wire harness. 

• Connect the pocket tester (Q. x 1 ) to the fuel 
pump coupler (fuel pump side) as shown. 



Tester positive probe - 
Tester negative probe 



blue/black © 

► black (2) 




8-53 



FUEL PUMP SYSTEM 



ELEC 


— _ 


+ 





EB808.*.10 

CHECKING THE FUEL PUMP 



A WARNING 



Gasoline is extremely flammable and under 
certain circumstances there can be a dan- 
ger of an explosion or fire. Be extremely 
careful and note the following points: 
•Stop the engine before refuelling. 

• Do not smoke and keep away from open 
flames, sparks or any other source of fire. 

• If you do accidentally spill gasoline, wipe it 
up immediately with dry rags. 

•If gasoline touches the engine when it is 
hot, a fire may occur. Therefore, make sure 
that the engine is completely cool before 
performing the following test. 




1. Check: 
•fuel pump operation 



a. Fill the fuel tank. 

b. Put the end of the fuel hose into an open con- 
tainer. 

c. Connect the battery (12 V) to the fuel pump 
coupler as shown. 



Battery positive lead -+ blue/black (T) 
Battery negative lead -► black (2) 



d. If fuel flows out of the fuel hose, the fuel 
pump is OK. If fuel does not flow, replace the 
fuel pump. 



8-54 



/" 



SELF-DIAGNOSIS 



ELEC 


_ _ 


+ 





SELF-DIAGNOSIS 

The YZF-R6 L/YZF-R6CL features a self-diagnosing system for the following circuit(-s): 

•throttle position sensor 

•fuel level indicator light 
If any of these circuits are defective, their respective condition codes will be displayed on the tachome- 
ter when the main switch is set to "ON" (irrespective of whether the engine is running or not) 



Circuit 



Throttle posi- 
tion sensor 



Fuel level indi- 
cator light 



Defect(-s) 



• Disconnected 
'Short-circuit 
' Locked 



> Improper connec- 
tion 



System response 



•The ignitor unit stays set to the 
wide-open throttle ignition timing. 
The motorcycle can be ridden. 

•The tachometer displays the 
condition code. 



-The tachometer displays the 
condition code. 



Condition code 



3,000 r/min 



8,000 r/min 



Tachometer display sequence 



Revolution 
(x 10 3 r/min) 



10 



(j) r/min ... 3 seconds 
(2) Condition code ... 2.5 seconds 
Engine speed ... 3 seconds 




Tachometer display 



Engine speed 



h~ Time (seconds) 



When more than one item is being monitored, the tachometer needle displays the condition codes in 
ascending order, cycling through the sequence repeatedly. 
If the engine is stopped, the engine speed (3) is r/min. 



8-55 



SELF-DIAGNOSIS 



ELEC 


™ ■■ 


+ 





TROUBLESHOOTING 



The tachometer starts to display the self- 
diagnosis sequence. 



Check: 

1. throttle position sensor 

2. fuel level indicator light 

NOTE: 



•Before troubleshooting, remove the following 
part(-s): 

1) rider seat 

2) fuel tank 

3) air filter case 

4) right side cowling inner panel 

5) right side cowling 

•Troubleshoot with the following special 
tool(-s). 



P* 



Pocket tester 
90890-03112 



1 . Throttle position sensor 

CIRCUIT DIAGRAM 









fi/B 


fr/B 


Gy 


B 


W 








j= 


r| '' : 


I 




W/R 


L 


V/B 


Sb 




y 


LJR 


UB 


B/L 











13 



^ V_|Ly 






0=££ 



f B/L-C 

- W/R4 



VCC 

TP 



TA SP 
El N 



rxi "" 



io 04 



i^> 



-<y- 



liSGip 



@ Throttle position sensor 
(t4)CDI unit 



1 . Wire harness 



•Check the wire harness for continuity. 

Refer to "CIRCUIT DIAGRAM". 
• Is the wire harness OK? 







YES 



# 



NO 



Repair or replace the 
wire harness. 



2. Throttle position sensor 



•Check the throttle position sensor for conti- 
nuity. 

Refer to "CHECKING AND ADJUSTING 
THE THROTTLE POSITION SENSOR" in 
chapter 6. 

• Is the throttle position sensor OK? 







YES 



f 



NO 



Replace the CDI unit. 



Replace the throttle 
position sensor. 



8-56 



2. Fuel level indicator light 

CIRCUIT DIAGRAM 



EMttfrm:!;:' 



IAtt-htJ;hli:lM 



@ Fuel sender 
@CDI unit 

@ Fuel level indicator light 
@ Combination meter 




SELF-DIAGNOSIS 



ELEC 


<m tm 


+ 





1 . Fuel level indicator light LED 



• Check the LED of the fuel level indicator light. 
Refer to "CHECKING THE LEDs". 

• Is the fuel level indicator light LED OK? 







YES 



f 



NO 



Repair the fuel level 
indicator light LED. 



2. Fuel sender 



• Disconnect the fuel sender coupler from the 
wire harness. 

- Connect the pocket tester (W x 1 ) to the fuel 
sender coupler as shown. 



Tester positive probe -► green (T) 
Tester negative probe -+ black (2) 




ID 



•Check the fuel sender for continuity. 
• Is the fuel sender OK? 







YES 



f 



NO 



Replace the fuel 
sender. 



8-57 



SELF-DIAGNOSIS 



ELEC 




+ 





3. Wire harness 



'Check the wire harness for continuity. 
Refer to "CIRCUIT DIAGRAM". 
■ Is the wire harness OK? 







YES 



f 



NO 



Replace the CDI unit. 



Replace or replace 
the wire harness. 



8-58 



TRBL 
SHTG 


9 

• 



CHAPTER 9. 
TROUBLESHOOTING 

STARTING PROBLEMS 9-1 

ENGINE g_i 

FUEL SYSTEM 9-1 

ELECTRICAL SYSTEMS 9-1 

INCORRECT ENGINE IDLING SPEED 9-2 

ENGINE 9_2 

FUEL SYSTEM 9-2 

ELECTRICAL SYSTEMS 9-2 

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-2 

ENGINE 9_2 

FUEL SYSTEM 9-2 

FAULTY GEAR SHIFTING 9-2 

SHIFTING IS DIFFICULT 9-2 

SHIFT PEDAL DOES NOT MOVE 9-2 

JUMPS OUT OF GEAR 9-2 

FAULTY CLUTCH 9-3 

CLUTCH SLIPS 9-3 

CLUTCH DRAGS 9-3 

OVERHEATING 9-3 

ENGINE 9.3 

COOLING SYSTEM 9.3 

FUEL SYSTEM 9.3 

CHASSIS 9.3 

ELECTRICAL SYSTEMS 9.3 

OVERCOOLING 9.3 

COOLING SYSTEM 9.3 

POOR BRAKING PERFORMANCE 9-4 

FAULTY FRONT FORK LEGS 9-4 

LEAKING OIL 9.4 

MALFUNCTION 9.4 



TRBL 
SHTG 


9 

• 



UNSTABLE HANDLING 9-4 

FAULTY LIGHTING AND SIGNALING SYSTEMS 9-5 

HEADLIGHT DOES NOT LIGHT 9-5 

HEADLIGHT BULB BURNT OUT 9-5 

TAIL/BRAKE LIGHT DOES NOT LIGHT 9-5 

TAIL/BRAKE LIGHT BULB BURNT OUT 9-5 

TURN SIGNAL DOES NOT LIGHT 9-5 

TURN SIGNAL BLINKS SLOWLY 9-5 

TURN SIGNAL REMAINS LIT 9-5 

TURN SIGNAL BLINKS QUICKLY 9-5 

HORN DOES NOT SOUND 9-5 



STARTING PROBLEMS 



TRBL 
SHTG 


9 

• 



TROUBLESHOOTING 



NOTE: . 

The following guide for troubleshooting does not cover all the possible causes of trouble. It should be 
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure is this manual for 
checks, adjustments, and replacement of parts. 



STARTING PROBLEMS 

ENGINE 

Cylinders and cylinder head(-s) 

• Loose spark plug 

• Loose cylinder head 

• Damaged cylinder head gasket 
•Worn or damaged cylinder 

• Incorrect valve clearance 

• Incorrectly sealed valve 

• Incorrect valve-to-valve-seat contact 

• Incorrect valve timing 

• Faulty valve spring 

• Seized valve 

Pistons and piston rings 

• Incorrectly installed piston ring 

• Damaged, worn or fatigued piston ring 

• Seized piston ring 

• Seized or damaged piston 
Air filter 

• Incorrectly installed air filter 
•Clogged air filter element 
Crankcase and crankshaft 

• Incorrectly assembled crankcase 

• Seized crankshaft 



ELECTRICAL SYSTEMS 
Battery 

• Faulty battery 

• Discharged battery 
Fuses 

• Blown, damaged or incorrect fuse 

• Incorrectly installed fuse 
Spark plugs 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 

• Fouled spark plug 

•Worn or damaged electrode 
•Worn or damaged insulator 
•Faulty spark plug cap 
Ignition coils 
•Damaged ignition coil 

• Broken or shorted primary or secondary coils 



FUEL SYSTEM 
Fuel tank 

• Empty fuel tank 
•Clogged fuel filter 

•Clogged fuel tank breather hose 

• Deteriorated or contaminated fuel 
Fuel pump 

•Faulty fuel pump 

• Faulty fuel pump relay 
Fuel cock 

•Clogged or damaged fuel hose 
Carburetors 

• Deteriorated or contaminated fuel 

• Clogged pilot jet 
•Clogged pilot air passage 
•Sucked-in air 

• Damaged float 
•Worn needle valve 

• Incorrectly installed needle valve seat 
•Incorrect fuel level 

• Incorrectly installed pilot jet 

• Clogged starter jet 

• Faulty starter plunger 

• Incorrectly adjusted starter cable 



Ignition system 

• Faulty CDI unit 

• Faulty pickup coil 
Switches and wiring 

• Faulty main switch 

• Faulty engine stop switch 
•Broken or shorted wiring 

• Faulty neutral switch 

• Faulty start switch 

• Faulty sidestand switch 

• Faulty clutch switch 

• Incorrectly grounded circuit 

• Loose connections 
Starting system 

• Faulty starter motor 

• Faulty starter relay 

• Faulty starting circuit cutoff relay 

• Faulty starter clutch 



9-1 



INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND- 
HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING 



TRBL 
SHTG 


9 

• 



INCORRECT ENGINE IDLING SPEED 

ENGINE 

Cylinders and cylinder head 

• Incorrect valve clearance 

• Damaged valve train components 
Air filter 

•Clogged air filter element 

FUEL SYSTEM 
Carburetors 

• Faulty starter plunger 

• Loose or clogged pilot jet 

• Loose or clogged pilot air jet 

• Damaged or loose carburetor joint 

• Incorrectly synchronized carburetors 

• Incorrectly adjusted engine idling speed 
(throttle stop screw) 

• Incorrect throttle cable free play 

• Flooded carburetor 



ELECTRICAL SYSTEMS 
Battery 

• Faulty battery 

• Discharged battery 
Spark plugs 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 

• Fouled spark plug 

•Worn or damaged electrode 
•Worn or damaged insulator 

• Faulty spark plug cap 
Ignition coils 

• Broken or shorted primary or secondary coils 

• Faulty spark plug lead 
•Damaged ignition coil 
Ignition system 

• Faulty ignition unit 

• Faulty pickup coil 



POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 

Refer to "STARTING PROBLEMS". 

ENGINE FUEL SYSTEM 

Air filter Carburetors 

• Clogged air filter element • Faulty diaphragm 
Air intake system • Incorrect fuel level 

• Clogged air ducts • Loose or clogged main jet 

Fuel pump 

• Faulty fuel pump 



FAULTY GEAR SHIFTING 

SHIFTING IS DIFFICULT 

Refer to "CLUTCH DRAGS". 
SHIFT PEDAL DOES NOT MOVE 
Shift shaft 

• Incorrectly adjusted shift rod 

• Bent shift shaft 

Shift drum and shift forks 

• Foreign object in a shift drum groove 

• Seized shift fork 

• Bent shift fork guide bar 
Transmission 

•Seized transmission gear 

• Foreign object between transmission gears 

• Incorrectly assembled transmission 



JUMPS OUT OF GEAR 
Shift shaft 

• Incorrect shift pedal position 

• Incorrectly returned stopper lever 
Shift forks 

•Worn shift fork 
Shift drum 

• Incorrect axial play 
•Worn shift drum groove 
Transmission 

•Worn gear dog 



9-2 



FAULTY CLUTCH/OVERHEATING/OVERCOOLING 



TRBL 
SHTG 


9 

• 



EB904000 



FAULTY CLUTCH 

CLUTCH SLIPS 
Clutch 

• Incorrectly assembled clutch 

• Incorrectly adjusted clutch cable 

• Loose or fatigued clutch spring 

• Worn friction plate 
•Worn clutch plate 
Engine oil 
•Incorrect oil level 

• Incorrect oil viscosity (low) 

• Deteriorated oil 



CLUTCH DRAGS 
Clutch 

• Unevenly tensioned clutch spring plate 
•Warped pressure plate 

•Bent clutch plate 

• Swollen friction plate 
•Bent clutch pull rod 

• Damaged clutch boss 

•Burnt primary driven gear bushing 

• Match marks not aligned 
Engine oil 

• Incorrect oil level 

• Incorrect oil viscosity (high) 

• Deteriorated oil 



OVERHEATING 

ENGINE 

Clogged coolant passages 

Cylinder head(-s) and piston(-s) 

• Heavy carbon buildup 
Engine oil 

•Incorrect oil level 

• Incorrect oil viscosity 

• Inferior oil quality 

COOLING SYSTEM 
Coolant 

• Low coolant level 
Radiator 

• Damaged or leaking radiator 

• Faulty radiator cap 

• Bent or damaged radiator fin 
Water pump 

• Damaged or faulty water pump 
Thermostat 

•Thermostat stays closed 
Oil cooler 

•Clogged or damaged oil cooler 
Hoses and pipes 

• Damaged hose 
•Incorrectly connected hose 

• Damaged pipe 

• Incorrectly connected pipe 



FUEL SYSTEM 
Carburetors 

• Incorrect main jet setting 
•Incorrect fuel level 

• Damaged or loose carburetor joint 
Air filter 

•Clogged air filter element 

CHASSIS 
Brakes 

• Dragging brake 

ELECTRICAL SYSTEMS 
Spark plugs 

• Incorrect spark plug gap 

• Incorrect spark plug heat range 
Ignition system 

• Faulty CDI unit 



OVERCOOLING 

COOLING SYSTEM 
Thermostat 

• Thermostat stays open 



9-3 



POOR BRAKING PERFORMANCE/FAULTY FRONT FORK 

LEGS/UNSTABLE HANDLING 



POOR BRAKING PERFORMANCE 

• Worn brake pad 
•Worn brake disc 

•Air in hydraulic brake system 
•Leaking brake fluid 

• Faulty brake caliper piston seal 



TRBL 
SHTG 


9 

• 



• Loose union bolt 

• Damaged brake hose 

•Oil or grease on the brake disc 
•Oil or grease on the brake pad 

• Incorrect brake fluid level 



FAULTY FRONT FORK LEGS 

LEAKING OIL 

• Bent, damaged or rusty inner tube 

• Damaged outer tube 

• Incorrectly installed oil seal 

• Damaged oil seal lip 

• Incorrect oil level (high) 

• Loose damper rod assembly bolt 

• Damaged damper rod assembly bolt copper 
washer 

• Damaged cap bolt O-ring 



MALFUNCTION 

• Bent or damaged inner tube 

• Bent or damaged outer tube 
•Damaged fork spring 

•Worn or damaged outer tube busing 

• Bent or damaged damper rod 

• Incorrect oil viscosity 

• Incorrect oil level 



UNSTABLE HANDLING 

Handlebars 

• Bent or incorrectly installed right handlebar 

• Bent or incorrectly installed left handlebar 
Steering head components 

• Incorrectly installed upper bracket 

• Incorrectly installed lower bracket 
(incorrectly tightened ring nut) 

• Bent steering stem 

• Damaged ball bearing or bearing race 
Front fork legs 

• Unevenoil levels (both front fork legs) 

• Unevenly tensioned fork spring (both front fork 
legs) 

• Damaged fork spring 

• Bent or damaged inner tube 

• Bent or damaged outer tube 



Swingarm 

•Worn bearing or bushing 

• Bent or damaged swingarm 
Rear shock absorber assembly 

• Faulty rear shock absorber spring 
•Leaking oil or gas 

Tires 

•Uneven tire pressures (front and rear) 

• Incorrect tire pressure 
•Uneven tire wear 
Wheels 

• Incorrect wheel balance 

• Deformed cast wheel 

• Damaged wheel bearing 

• Bent or loose wheel axle 

• Excessive wheel runout 
Frame 

• Bent frame 

• Damaged steering head pipe 

• Incorrectly installed bearing race 



9-4 



FAULTY LIGHTING AND SIGNALING SYSTEMS 



TRBL 
SHTG 


9 

• 



FAULTY LIGHTING AND SIGNALING 

HEADLIGHT DOES NOT LIGHT 

•Wrong headlight bulb 

•Too many electrical accessories 

• Hard charging 

• Incorrect connection 

• Incorrectly grounded circuit 

• Poor contacts (main or light switch) 
•Burnt-out headlight bulb 

HEADLIGHT BULB BURNT OUT 

•Wrong headlight bulb 

• Faulty battery 
•Faulty rectifier/ regulator 

• Incorrectly grounded circuit 

• Faulty main switch 

• Faulty light switch 
•Headlight bulb life expired 

TAIL/BRAKE LIGHT DOES NOT LIGHT 

•Wrong tail/brake light bulb 
•Too may electrical accessories 

• Incorrect connection 
•Burnt-out tail/brake light bulb 

TAIL/BRAKE LIGHT BULB BURNT OUT 

•Wrong tail/brake light bulb 

• Faulty battery 

• Incorrectly adjusted rear brake light switch 
•Tail/brake light bulb life expired 



SYSTEMS 

TURN SIGNAL DOES NOT LIGHT 

• Faulty turn signal switch 

• Faulty turn signal relay 
•Burnt-out turn signal bulb 

• Incorrect connection 

• Damaged or faulty wire harness 

• Incorrectly grounded circuit 

• Faulty battery 

•Blown, damaged or incorrect fuse 

TURN SIGNAL BLINKS SLOWLY 

• Faulty flasher relay 

• Faulty main switch 

• Faulty turn signal switch 
•Wrong turn signal bulb 

TURN SIGNAL REMAINS LIT 

• Faulty flasher relay 
•Burnt-out-turn signal bulb 

TURN SIGNAL BLINKS QUICKLY 

• Incorrect turn signal bulb 

• Faulty flasher relay 

• Burnt-out turn signal bulb 

HORN DOES NOT SOUND 

• Incorrectly adjusted horn 

• Damaged or faulty horn 

• Faulty main switch 

• Faulty horn switch 

• Faulty battery 

• Blown, damaged or incorrect fuse 

• Faulty wire harness 



9-5 



YZF-R6 L/YZF-R6CL WIRING DIAGRAM 






Br 




i* 


Dgi R GPl 




' 


B 


^l-V3 


- 


Cfiisb jal | 



f G( 


R 


DgTiW 


— A — .91 


w 


W-v 


(f! 


11 


Sb 


Ch|- 


>8 | % ! B 


L"f 


*C 


ftV: 



CO«D HEAD LIGHT 




© Main switch 

© Fuse (backup) 

(3) Rectifier/ regulator 

(4) AC magneto 

(5) Battery 

(6) Fuse (main) 
© Starter relay 
© Starter motor 

@ Starting circuit cutoff relay 

© Fuel pump 

© Sidestand switch 

@ Fuel sender 

© Throttle position sensor 

© CDI unit 

© Ignition coil #1 

© Ignition coil #4 

© Ignition coil #2 

@ Ignition coil #3 

© Spark plug 

@ Pickup coil 

© Neutral switch 

@ Speed sensor 

@ Thermo unit 

© Meter assembly 

@ Fuel level indicator light 

@ Oil level/coolant temperature 

warning light 
@ Neutral indicator light 
© Tachometer 
© Combination meter 
@ High beam indicator light 
@ Turn signal indicator light 
© Illumination light 
@ Handlebar switch (left) 
© Dimmer switch 
@ Horn switch 
© Horn 
© Clutch switch 
@ Turn signal switch 
@ Flasher relay 

© Front turn signal/position light (L) 
© Front turn signal/position light (R) 
© Rear turn signal light (L) 
@ Rear turn signal light (R) 
© Headlight 
© Headlight relay (Hi) 
© Headlight relay (Lo) 
© Tail/brake light 
© Radiator fan motor 
@ Thermo switch 
© Fuse (radiator fan motor) 
© Fuse (headlight) 
@ Fuse (signaling system) 
© Fuse (ignition) 
© Oil level relay 
@ Oil level switch 
© Rear brake light switch 
© Handlebar switch (right) 
© Front brake light switch 
© Engine stop switch 
@ Start switch 
@ Diode 1 
© Diode 2 



COLOR CODE 

B Black 

Br Brown 

Ch Chocolate 

Dg .... Dark green 

G Green 

Gy .... Gray 

L Blue 

O Orange 

P Pink 

R Red 

Sb Sky blue 

W White 



Y .... 


. Yellow 


L/B.. 


. Blue/Black 


B/L... 


. Black/Blue 


. L/R . 


. Blue/Red 


B/R . 


. Black/ Red 


L/W . 


. Blue/White 


B/Y . 


. Black/Yellow 


L/Y.. 


. Blue/Yellow 


B/W . 


. Black/White 


O/B . 


. Orange/Black 


Br/B . 


. Brown/Black 


R/B . 


. Red /Black 


Br/L . 


. Brown/Blue 


R/L . 


. Red /Blue 


Br/W 


. Brown/White 


R/W. 


. Red/White 


G/R . 


. Green/ Red 


R/Y . 


. Red /Yellow 


G/W . 


. Green/White 


W/G. 


. White/Green 


G/Y . 


. Green/Yellow 


W/R . 


. White/ Red 


Gy/B 


. Gray/Black 


W/Y . 


. White/Yellow 



Y/B 



Yellow/Black